mcl - bosch rexroth

MCL

Ironless Linear Motors

Project Planning ManualR911330592

Edition 06

MCLIronless Linear Motors

Project Planning Manual

DOK-MOTOR*-MCL********-PR06-EN-P

RS-82551fe8ab5f14650a6846a001697ff3-9-en-US-3

Record of revisions Edition 06, 2020-06See tab. 1-1 "Record of revisions" on page 4.

Copyright © Bosch Rexroth AG 2020All rights reserved, also regarding any disposal, exploitation, reproduction,editing, distribution, as well as in the event of applications for industrial prop‐erty rights.

Liability The specified data is intended for product description purposes only and shallnot be deemed to be a guaranteed characteristic unless expressly stipulatedin the contract. All rights are reserved with respect to the content of this docu‐mentation and the availability of the product.

Note This document has been printed on chlorine-free bleached paper.

Title

Type of Documentation

Document Typecode

Internal File Reference

MCL Ironless Linear Motors

Table of ContentsPage

1 Introduction to the product............................................................................................. 11.1 Fields of application................................................................................................................................ 11.2 Basic features......................................................................................................................................... 21.3 Setup...................................................................................................................................................... 21.4 Comparison ironless with ferreous linear motors.................................................................................... 31.5 Motor power spectrum............................................................................................................................ 41.6 About this documentation....................................................................................................................... 41.6.1 Editions of this documentation............................................................................................................. 41.6.2 Document structure............................................................................................................................. 51.6.3 Information presentation...................................................................................................................... 51.6.4 Further documentation........................................................................................................................ 61.6.5 Standards............................................................................................................................................ 71.6.6 Additional components........................................................................................................................ 71.6.7 Your feedback..................................................................................................................................... 7

2 Important instructions on use......................................................................................... 92.1 Appropriate use...................................................................................................................................... 92.1.1 Introduction.......................................................................................................................................... 92.1.2 Areas of use and application............................................................................................................... 92.2 Inappropriate use.................................................................................................................................. 10

3 Safety instructions for electric drives and controls....................................................... 113.1 Definitions of terms............................................................................................................................... 113.2 General information.............................................................................................................................. 123.2.1 Using the Safety instructions and passing them on to others............................................................ 123.2.2 Requirements for safe use................................................................................................................ 123.2.3 Hazards by improper use.................................................................................................................. 133.3 Instructions with regard to specific dangers.......................................................................................... 143.3.1 Protection against contact with electrical parts and housings........................................................... 143.3.2 Protective extra-low voltage as protection against electric shock .................................................... 153.3.3 Protection against dangerous movements........................................................................................ 163.3.4 Protection against electromagnetic and magnetic fields during operation and mounting.................. 173.3.5 Protection against contact with hot parts........................................................................................... 183.3.6 Protection during handling and mounting.......................................................................................... 183.3.7 Battery safety..................................................................................................................................... 183.3.8 Protection against pressurized systems............................................................................................ 193.4 Explanation of signal words and the Safety alert symbol..................................................................... 20

4 Technical data.............................................................................................................. 214.1 Explanations about technical data........................................................................................................ 214.1.1 Introduction........................................................................................................................................ 214.1.2 Operating behavior............................................................................................................................ 214.1.3 Description of specified sizes............................................................................................................ 25

MCL Ironless Linear Motors I

Table of Contents

R911330592_Edition 06 Bosch Rexroth AG

2 IndraSize............................................................................................................................................... 264.3 General technical data.......................................................................................................................... 274.4 Frame size 015..................................................................................................................................... 284.4.1 Data sheet MCP015.......................................................................................................................... 284.4.2 Data sheet MCS015.......................................................................................................................... 284.4.3 Motor characteristic curve frame size 015......................................................................................... 294.5 Frame size 020..................................................................................................................................... 304.5.1 Data sheet MCP020.......................................................................................................................... 304.5.2 Data sheet MCS020.......................................................................................................................... 304.5.3 Motor characteristic curves frame size 020....................................................................................... 314.6 Frame size 030..................................................................................................................................... 334.6.1 Data Sheet MCP030.......................................................................................................................... 334.6.2 Data sheet MCS030.......................................................................................................................... 334.6.3 Motor characteristic curve frame size 030......................................................................................... 344.7 Frame size 040..................................................................................................................................... 364.7.1 Data sheet MCP040.......................................................................................................................... 364.7.2 Data sheet MCS040.......................................................................................................................... 374.7.3 Motor characteristic curves frame size 040....................................................................................... 374.8 Frame size 070..................................................................................................................................... 404.8.1 Data sheet MCP070.......................................................................................................................... 404.8.2 Data sheet MCS070.......................................................................................................................... 414.8.3 Motor characteristic curve frame size 070......................................................................................... 41

5 Dimension sheets........................................................................................................ 455.1 Specifications........................................................................................................................................ 455.1.1 Air gap and installation height........................................................................................................... 455.1.2 Installation dimensions MCL015........................................................................................................ 465.1.3 Installation dimensions MCL020 ... 070............................................................................................. 475.1.4 Parallelism and symmetry of machine parts...................................................................................... 485.2 Dimensional sheets for MCL015........................................................................................................... 505.3 Dimensional sheets MCL020................................................................................................................ 525.4 Dimensional sheets for MCL030........................................................................................................... 545.5 Dimensional sheets MCL040................................................................................................................ 565.6 Dimensional sheets MCL070................................................................................................................ 58

6 Identification................................................................................................................. 616.1 Type codes .......................................................................................................................................... 616.1.1 General.............................................................................................................................................. 616.1.2 Type codes primary part MCP........................................................................................................... 616.1.3 Type code MCS secondary part........................................................................................................ 636.1.4 Type code frame size 015................................................................................................................. 646.1.5 Type code frame size 020................................................................................................................. 666.1.6 Type code frame size 030................................................................................................................. 686.1.7 Type code frame size 040................................................................................................................. 706.1.8 Type code frame size 070................................................................................................................. 72

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Bosch Rexroth AG R911330592_Edition 06

2 Identification.......................................................................................................................................... 746.2.1 Identification MCP primary part ........................................................................................................ 746.2.2 Identification MCS secondary part..................................................................................................... 756.2.3 Certification mark............................................................................................................................... 76

7 Accessories and options.............................................................................................. 777.1 Hall unit................................................................................................................................................. 777.1.1 General.............................................................................................................................................. 777.1.2 Hall unit function................................................................................................................................ 777.1.3 Hall unit assembly/Disassembly........................................................................................................ 807.1.4 Ordering code separate Hall unit....................................................................................................... 817.2 Hall unit adapter box SHL03.1 for digital Hall unit................................................................................ 817.2.1 General mode of functioning............................................................................................................. 817.2.2 Ordering code.................................................................................................................................... 81

8 Connection technique.................................................................................................. 838.1 Notes.................................................................................................................................................... 838.2 Power connection ................................................................................................................................ 838.2.1 Connection cable on primary part...................................................................................................... 838.2.2 Assembly Connection cable on primary part..................................................................................... 858.2.3 Connection power ............................................................................................................................. 868.2.4 Installation of power connection........................................................................................................ 888.3 Sensors................................................................................................................................................. 908.3.1 Connection temperature sensor........................................................................................................ 908.3.2 Connection Hall unit.......................................................................................................................... 908.3.3 Assembly Hall unit connection cable................................................................................................. 928.3.4 Connect digital Hall unit..................................................................................................................... 938.3.5 Connect analog Hall unit................................................................................................................... 948.4 Length measuring system .................................................................................................................... 94

9 Application and construction instructions..................................................................... 979.1 Mode of functioning.............................................................................................................................. 979.2 Motor design......................................................................................................................................... 979.2.1 Design primary part .......................................................................................................................... 979.2.2 Design secondary part ...................................................................................................................... 989.2.3 Frame size and frame length............................................................................................................. 999.3 Installation altitude and ambient conditions........................................................................................ 1009.4 Environmental conditions during operation......................................................................................... 1019.5 Type of protection............................................................................................................................... 1029.6 Acceptances and approvals................................................................................................................ 1029.6.1 CE.................................................................................................................................................... 1029.6.2 EAC................................................................................................................................................. 1029.6.3 RoHS............................................................................................................................................... 1039.6.4 China RoHS 2.................................................................................................................................. 1039.7 Magnetic fields.................................................................................................................................... 103

MCL Ironless Linear Motors III

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8 Noise emission................................................................................................................................... 1049.9 Thermal behavior................................................................................................................................ 1059.10 Motor temperature monitoring............................................................................................................ 1079.11 Feed force at reduced covering between primary and secondary part.............................................. 1089.12 Requirements on the machine design................................................................................................ 1109.12.1 General............................................................................................................................................ 1109.12.2 Mass reduction................................................................................................................................ 1109.12.3 Mechanical rigidity........................................................................................................................... 1109.12.4 Protection of the motor installation space........................................................................................ 1129.13 Arrangement of motor components.................................................................................................... 1129.13.1 Single arrangement......................................................................................................................... 1129.13.2 Several motors per axis................................................................................................................... 1139.13.3 Arrangement of secondary parts..................................................................................................... 1199.13.4 Vertical axis .................................................................................................................................... 1199.14 Length measuring system................................................................................................................... 1209.14.1 General............................................................................................................................................ 1209.14.2 Selection criteria for length measuring system ............................................................................... 1209.15 Linear guiding systems....................................................................................................................... 1219.16 Braking systems and holding devices................................................................................................. 1229.17 End position shock absorber ............................................................................................................. 1239.18 Axis cover systems............................................................................................................................. 1239.19 Motor control and regulation............................................................................................................... 1239.19.1 General............................................................................................................................................ 1239.19.2 Drive controllers............................................................................................................................... 1249.19.3 Control systems............................................................................................................................... 1249.20 Deactivation upon EMERGENCY STOP and in the event of a malfunction ...................................... 1259.20.1 General............................................................................................................................................ 1259.20.2 Deactivation by the drive................................................................................................................. 1259.20.3 Deactivation by a master control..................................................................................................... 1269.20.4 Deactivation via mechanical braking device.................................................................................... 1269.20.5 Response to a power outage .......................................................................................................... 1269.20.6 Short-circuit of DC bus.................................................................................................................... 1289.21 Position and velocity resolution.......................................................................................................... 1289.21.1 Drive internal position resolution and position accuracy ................................................................. 1289.21.2 Velocity resolution........................................................................................................................... 1299.22 Thermal connection - Installation modes............................................................................................ 1299.23 Operation at or near motor standstill.................................................................................................. 132

10 Motor-control combinations........................................................................................ 13310.1 General............................................................................................................................................... 13310.2 Motor-control combinations with NYCe 4000..................................................................................... 13310.3 Motor-control combinations with IndraDrive Cs.................................................................................. 134

11 Motor dimensioning.................................................................................................... 13511.1 General procedure.............................................................................................................................. 135

IV

Table of Contents



2 Basic formulae.................................................................................................................................... 13611.2.1 General movement equations ........................................................................................................ 13611.2.2 Feed forces...................................................................................................................................... 13711.2.3 Average velocity.............................................................................................................................. 14011.2.4 Trapezoidal velocity profile.............................................................................................................. 14111.2.5 Trapezoidal velocity profile.............................................................................................................. 14511.2.6 Sinusoidal velocity profile ............................................................................................................... 14611.3 Duty cycle and feed force................................................................................................................... 14911.3.1 General............................................................................................................................................ 14911.3.2 Determining the duty cycle.............................................................................................................. 14911.4 Determining the drive power............................................................................................................... 15011.4.1 General............................................................................................................................................ 15011.4.2 Continuous power ........................................................................................................................... 15011.4.3 Maximum output.............................................................................................................................. 15111.4.4 Power loss ...................................................................................................................................... 15211.5 Energy regeneration .......................................................................................................................... 15211.6 Efficiency............................................................................................................................................ 153

12 Handling, transport and storage................................................................................. 15512.1 Delivery status and packaging............................................................................................................ 15512.1.1 Primary parts................................................................................................................................... 15512.1.2 Secondary parts.............................................................................................................................. 15512.2 Testing of motor components............................................................................................................. 15512.2.1 Factory checks of the motor components ....................................................................................... 15512.3 Transport and storage........................................................................................................................ 15612.3.1 Notes about transport...................................................................................................................... 15612.3.2 Information on storage..................................................................................................................... 157

13 Assembly................................................................................................................... 15913.1 Basic precondition.............................................................................................................................. 15913.2 Arrangement of motor components.................................................................................................... 15913.3 Installation of motor components........................................................................................................ 16013.4 Air-gap, parallelism and symmetry of the motor components............................................................. 16013.5 Fastening secondary part................................................................................................................... 16113.6 Fastening the primary part.................................................................................................................. 16313.7 Electrical connection .......................................................................................................................... 165

14 Commissioning, operation and maintenance............................................................. 16714.1 General............................................................................................................................................... 16714.2 General requirements ........................................................................................................................ 16714.2.1 General............................................................................................................................................ 16714.2.2 Checking all electrical and mechanical components....................................................................... 16714.2.3 Tools................................................................................................................................................ 16814.3 General commissioning procedure..................................................................................................... 16814.4 Parameterization................................................................................................................................. 170

MCL Ironless Linear Motors V

Table of Contents


4.1 General............................................................................................................................................ 17014.4.2 Entering motor parameters.............................................................................................................. 17014.4.3 Motor parameter at parallal arrangement........................................................................................ 17014.4.4 Entering length measuring system parameter................................................................................. 17114.4.5 Entering drive limitations and application-related parameters......................................................... 17214.5 Determining the polarity of the linear scale......................................................................................... 17314.6 Commutation adjustment.................................................................................................................... 17414.6.1 General............................................................................................................................................ 17414.6.2 Sinusoidal procedure....................................................................................................................... 17614.6.3 Hall sensor procedure..................................................................................................................... 17614.6.4 Measuring procedure: Measuring of the relation between primary and secondary part.................. 17714.7 Setting and optimizing the control loop............................................................................................... 17914.7.1 General procedure........................................................................................................................... 17914.7.2 Parameter value assignments and optimization of Gantry axes..................................................... 18214.7.3 Estimating the moved mass using a velocity ramp ......................................................................... 18314.8 Maintenance and checking of motor components.............................................................................. 18514.8.1 General............................................................................................................................................ 18514.8.2 Checking of motor and additional components .............................................................................. 18514.8.3 Electrical check of motor components............................................................................................. 18514.9 Operation with third-party controllers.................................................................................................. 18614.10 Environmental protection and disposal .............................................................................................. 18614.10.1 Environmental protection................................................................................................................. 18614.10.2 Disposal........................................................................................................................................... 186

15 Service and support................................................................................................... 189

Index.......................................................................................................................... 191

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Table of Contents



1 Introduction to the product1.1 Fields of application

Continuously increasing demands on the economic benefit of electric ma‐chines require new problem-solving approaches to fulfill the requirements ondynamic, accuracy and synchronization. Conventional NC-drives, consistingof a rotary electrical motor and mechanical transmission elements like gear‐boxes, belt transmissions or gear rack pinions, cannot fulfill these demandsor, only with high effort.Due to the wide application range of ironless linear motors, medium to midgetmass can be moved and positioned high-dynamically and high-precisely.Based on the above-mentioned advantages, typical applications result for ex‐ample in:● Electronic, placement technology and manufacturing technology● Semi-conductor technology (z.B. wafer inspection and bonding)● Medical technology (e.g. transport of pipettes)● Solar technology (e.g. laser structuring)● Precision and ultra-precision machiningEven in other areas, for example, in machine tool industry, printing industryand especially in measuring technology, the advantages of this technologybecomes important.The ironless drive technology offers a lot of significant advantages in oppo‐site to a ferrous motor, without accepting disturbing ancillary effects like cog‐ging. For this reason, it is the optimum option for many applications.Significant advantages of ironless linear motors are:● Highest dynamic● Excellent control quality and synchronization● No magnetic attractive force, no detent torque● High-precision positioning behavior● Direct power transfer – no mechanical transmission elements like ball

screw, toothed belt, gear rack, etc.● High efficiency - low overhead● Maintenance-free drive (no wearing parts at the motor)● Simplified machine structure

For a comprehensive overview of all product groups of BoschRexroth Electric Drives and Controls, please refer to the onlineproduct catalog: http://www.boschrexroth.com/indradyn.

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Introduction to the product


http://www.boschrexroth.com/indradyn

1.2 Basic featuresProduct 3~ PM motorType MCL consist of MCP and MCSAmbient temperature during oper‐ation 0 … 40 °C

Protection class (EN 60034-5) IP00 (IP20)Cooling mode (EN 60034-6) IC410, Self-coolingInstallation altitude 0 ... 1000 m above MSL (without derating)Thermal class (EN 60034-1) 130 (B)Encoder system Hall sensor digital

SUP-E01-D15-MCP020SUP-E01-D30-MCP030/040/070Hall sensor analogSUP-E01-A15-MCP020SUP-E01-A30-MCP030/040/070

Electrical connection Connection cable with open cable endsshielded cable (3x power + 1x PE, 2x KTY)

Mechanical protection Primary part moulded with synthetic resinMagnets of the secondary part coated with synthetic resin

Motor ends

1.3 SetupIronless linear motors MCL consist of the components primary and secondarypart and have an optional Hall unit .The ironless primary part bears the electrically active part of the linear motorwith a winding, cast in plastics. The primary part carrier made of aluminumserves to assemble the primary part and for heat dissipation out of the pri‐mary part. A fastening of an optional Hall unit for position recording is pre‐pared on the primary part. Additionally, a temperature sensor is placed in thewinding. Hall unit and temperature sensor are available for all MCL, exceptfor the smalles frame size.The secondary part consists of an u-shaped iron yoke. The legs of the yokebear permanent magnets and surround the primary part. The line is built withthe secondary parts and can be realized as long as you want.The motor type designation depends on the ironless primary part. The desig‐nation is as follows:● MCL: Motor Coreless Linear● MCL: Motor Coreless Primary part● MCS: Motor Coreless Secondary part

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Fig. 1-1: Rexroth MCL example

1.4 Comparison ironless with ferreous linear motorsFerreous linear motors use the iron, in which the winding is inserted to bundlethe magnetic flow. Therewith, a very high force density is reached. Act up toa principle, very high magnetic attractive forces exist among the motor com‐ponents (primary and secondary part). These lead to detent force and due tosaturation effecst to other parasitic effects, such as e.g. winding influencesfor ripple of the operation force.No attractive forces exist among primary and secondary part towards ferre‐ous linear motors. Detent forces due to a slotting, existing for ferreous linearmotors are also not created. These aspects and the relatively small movedmass of the primary part allow a vergy high dynamic with high precision atthe same time.Additionally wearing mechanical components are not necessary due to directinstallation into the machine. Due to not existing mechanical elements, abacklash free, with minimum or without hysteresis afflicted drive train, isavailable.




1.5 Motor power spectrumNew solutions due to practice-oriented combination of motor technique withdigital intelligent drive controllers with ironless linear direct drive techniqueare available. The spectrum of ironless linear drive technique of BoschRexroth realized drives with feed forces of 10 N up to 3,300 N, accelerationup to 250 m/s² and maximum velocity up to 1,400 m/min. The following dia‐gram gives an overview of the performance spectrum :

Fig. 1-2: Perfomance spectrum Rexroth MCL

1.6 About this documentation1.6.1 Editions of this documentation

Edition Releasedate Notes

06 2020-06 Revision / supplement

05 2015-02 Ddetails about parallel arrangement added

04 2014-06 Details about commutation adjustment Chapter 14.6 amended

... ... ...

01 2011-01 First edition

Tab. 1-1: Record of revisions

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1.6.2 Document structureThis documentation includes safety-related guidelines, technical data andoperating instructions. The following table provides an overview of the con‐tents of this documentation.

Chapter Title Content

1 Introduction Product presentation / Notes regarding reading

2 Important instructions for useImportant safety instructions

3 Safety

4 Technical data

Product descrip‐tion

for planners anddesigners

5 Specifications

6 Type codes

7 Accessories

Practicefor operating and

maintenancepersonnel

8 Connection technique

9 Operating condition and applicationinstructions

10 Motor-control combination

11 Motor dimensioning

12 Handling, transport and storage

13 Installation

14 Startup, operation and mainte‐nance

15 Service & SupportAdditional information

16 Index

Tab. 1-2: Chapter structure

1.6.3 Information presentationSafety instructions The safety instructions in this documentation include signal words (danger,

warning, caution, note) and a signal symbol (acc. to ANSI Z535.6-2006).The signal word is intended to draw your attention to the safety instructionsand describes the seriousness of the danger. The warning triangle with excla‐mation mark indicates the danger for persons.

DANGER

Non-compliance with this safety instructions will result in death or severe per‐sonal injury.

WARNING

Non-compliance with this safety instructions can result in death or severepersonal injury.




CAUTION

Non-compliance with this safety instructions can result in moderate or minorpersonal injury.

NOTICE

Non-compliance with this safety instructions can result in material damage.

Safety symbols The following internationally standardized safety symbols and graphic sym‐bols are used in this documentation. The meaning of the symbols is descri‐bed in the table.Safety symbols Meaning

Warning against dangerous electric voltage

Warning against hot surfaces

Warning against overhead load

Electrostatic sensitive devices

No access for persons with cardiac pacemakers or implanted defibrilla‐tors.

Do not carry along metal parts or clocks.

Tab. 1-3: Meaning of safety signs

Markup The following markups are used for a user-friendly text information represen‐tation:

Reference to supplementary documentation

This note gives important information, which must be observed.

● Listings on the first level contain a bullet point– Listings on the second level contain a dash

1. Handling instructions are specified in numbered lists. Please complywith the order of the handling instructions.

1.6.4 Further documentationTo plan the drive-systems with MCL motors, it is possible that you need addi‐tional documentation referring the used devices. Rexroth provides the com‐plete product documentation in PDF format in the following Bosch Rexrothmedia directory:http://www.boschrexroth.com/various/utilities/mediadirectory/index.jsp

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http://www.boschrexroth.com/various/utilities/mediadirectory/index.jsp

1.6.5 StandardsThis documentation refers to German, European and international technicalstandards. Documents and sheets on standards are subject to copyright pro‐tection and may not be passed on to third parties by Rexroth. If need be,please contact the authorized sales outlets or, in Germany, directly:BEUTH Verlag GmbHBurggrafenstraße 610787 Berlin, GermanyTel. +49 (0)30-26 01-22 60Fax +49 (0)30-26 01-12 60Internet: http://www.din.de/beuthE-Mail:[email protected]

1.6.6 Additional componentsDocumentation for external systems which are connected to Bosch Rexrothcomponents are not included in the scope of delivery and must be ordereddirectly from the corresponding manufacturers.

1.6.7 Your feedbackYour experiences are an essential part of the improvement process of prod‐uct and documentation.Please send your feedback to:Bosch Rexroth AGDept. DC-AE/EPI5 (fs, mb)Buergermeister-Dr.-Nebel-Straße 297816 Lohr am Main, GermanyE-Mail: [email protected]




http://www.din.de/beuth

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2 Important instructions on use2.1 Appropriate use2.1.1 Introduction

Bosch Rexroth products are designed and manufactured using the lateststate-of-the-art-technology. Before shipping, all products are checked forsafety.However, the products may only be used in compliance with their appropriateuse. If they are not used as intended, property damage and personal injurymay occur.

Bosch Rexroth, as the manufacturer, does not provide any war‐ranty, assume any liability, or pay any damages for damagecaused by products not being used as intended. Any risks result‐ing from the products not being used as intended are the sole re‐sponsibility of the user.

Before using the products by Bosch Rexroth, the following condition prece‐dent must be fulfilled so as to ensure that they are used as intended:● Personnel that in any way uses our products must first read and under‐

stand the relevant safety instructions and be familiar with their appropri‐ate use.

● Hardware products must be left in their original condition, i.e. no struc‐tural changes may be made. Software products must not be decompiledand their source code must not be changed.

● Damaged or defective products must not be installed or put into opera‐tion.

● It must be ensured that products are installed in compliance with all reg‐ulations specified in the documentation.

2.1.2 Areas of use and applicationIronless linear motors MCL of Bosch Rexroth are intended for use as linearservo drive motors.For application-specific use of motors, drive controllers with various levels ofpower, DC bus voltage and different interfaces are available. For regulationand controlling of motors, additional sensors like length measuring systemsmust be connected.

● The motors may only be used with the accessories and at‐tachments specified in this documentation. Components thatare not explicitly specified must not be installed nor connec‐ted. The same applies for cables and lines.

● The device may only be operated in the explicitly specifiedconfigurations and combination of components and in com‐pliance with the respective functional description of the soft‐ware and firmware.

Before commissioning, every connected drive controller must be program‐med according to the specified motor function for the specified application.The motors may only be operated under the assembly, mounting and installa‐tion conditions, in the normal position, and under the environmental condi‐


Important instructions on use


tions (temperature, degree of protection, humidity, EMC etc.) specified in thisdocumentation.

2.2 Inappropriate useAny use of motors outside of the fields of application mentioned above or un‐der operating conditions and technical data other than those specified in thisdocumentation is considered as "non-intended use".MCL motors may not be used if● they are exposed to operating conditions that do not meet the specified

ambient conditions. For example, they may not be operated under wa‐ter, under extreme temperature fluctuations or extreme maximum tem‐peratures;

● the intended application range is not explicitly approved for BoschRexroth motors.

MCL motors are not suited to be operated directly on the powersupply.

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Important instructions on use



3 Safety instructions for electric drives and controls3.1 Definitions of terms

Application documentation Application documentation comprises the entire documentation used to in‐form the user of the product about the use and safety-relevant features forconfiguring, integrating, installing, mounting, commissioning, operating, main‐taining, repairing and decommissioning the product. The following terms arealso used for this kind of documentation: Operating Instructions, Commis‐sioning Manual, Instruction Manual, Project Planning Manual, Application De‐scription, etc.

Component A component is a combination of elements with a specified function, whichare part of a piece of equipment, device or system. Components of the elec‐tric drive and control system are, for example, supply units, drive controllers,mains choke, mains filter, motors, cables, etc.

Control system A control system comprises several interconnected control componentsplaced on the market as a single functional unit.

Device A device is a finished product with a defined function, intended for users andplaced on the market as an individual piece of merchandise.

Electrical equipment Electrical equipment encompasses all devices used to generate, convert,transmit, distribute or apply electrical energy, such as electric motors, trans‐formers, switching devices, cables, lines, power-consuming devices, circuitboard assemblies, plug-in units, control cabinets, etc.

Electric drive system An electric drive system comprises all components from mains supply to mo‐tor shaft; this includes, for example, electric motor(s), motor encoder(s), sup‐ply units and drive controllers, as well as auxiliary and additional compo‐nents, such as mains filter, mains choke and the corresponding lines and ca‐bles.

Installation An installation consists of several devices or systems interconnected for adefined purpose and on a defined site which, however, are not intended to beplaced on the market as a single functional unit.

Machine A machine is the entirety of interconnected parts or units at least one ofwhich is movable. Thus, a machine consists of the appropriate machine driveelements, as well as control and power circuits, which have been assembledfor a specific application. A machine is, for example, intended for processing,treatment, movement or packaging of a material. The term "machine" alsocovers a combination of machines which are arranged and controlled in sucha way that they function as a unified whole.

Manufacturer The manufacturer is an individual or legal entity bearing responsibility for thedesign and manufacture of a product which is placed on the market in the in‐dividual's or legal entity's name. The manufacturer can use finished products,finished parts or finished elements, or contract out work to subcontractors.However, the manufacturer must always have overall control and possessthe required authority to take responsibility for the product.

Product Examples of a product: Device, component, part, system, software, firmware,among other things.

Project Planning Manual A Project Planning Manual is part of the application documentation used tosupport the sizing and planning of systems, machines or installations.

Qualified persons In terms of this application documentation, qualified persons are those per‐sons who are familiar with the installation, mounting, commissioning and op‐eration of the components of the electric drive and control system, as well aswith the hazards this implies, and who possess the qualifications their work


Safety instructions for electric drives and controls


requires. To comply with these qualifications, it is necessary, among otherthings,● to be trained, instructed or authorized to switch electric circuits and devi‐

ces safely on and off, to ground them and to mark them.● to be trained or instructed to maintain and use adequate safety equip‐

ment.● to attend a course of instruction in first aid.

Qualified personnel for handlingfunctionally safe products

Individuals configuring, commissioning and operating functionally safe prod‐ucts must have the knowledge specified under "Qualified persons". Addition‐ally, these individuals must be familiar with technical safety concepts as wellas prevailing standards and regulations in the field of functional safety.

User A user is a person installing, commissioning or using a product which hasbeen placed on the market.

3.2 General information3.2.1 Using the Safety instructions and passing them on to others

Do not attempt to install and operate the components of the electric drive andcontrol system without first reading all documentation provided with the prod‐uct. Read and understand these safety instructions and all user documenta‐tion prior to working with these components. If you do not have the user doc‐umentation for the components, contact your responsible Bosch Rexrothsales partner. Ask for these documents to be sent immediately to the personor persons responsible for the safe operation of the components.If the component is resold, rented and/or passed on to others in any otherform, these safety instructions must be delivered with the component in theofficial language of the user's country.Improper use of these components, failure to follow the safety instructions inthis document or tampering with the product, including disabling of safety de‐vices, could result in property damage, injury, electric shock or even death.

3.2.2 Requirements for safe useRead the following instructions before initial commissioning of the compo‐nents of the electric drive and control system in order to eliminate the risk ofinjury and/or property damage. You must follow these safety instructions.● Bosch Rexroth is not liable for damages resulting from failure to observe

the safety instructions.● Read the operating, maintenance and safety instructions in your lan‐

guage before commissioning. If you find that you cannot completely un‐derstand the application documentation in the available language,please ask your supplier to clarify.

● Proper and correct transport, storage, mounting and installation, as wellas care in operation and maintenance, are prerequisites for optimal andsafe operation of the component.

● Only qualified persons may work with components of the electric driveand control system or within its proximity.

● Only use accessories and spare parts approved by Bosch Rexroth.● Follow the safety regulations and requirements of the country in which

the components of the electric drive and control system are operated.

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● Only use the components of the electric drive and control system in themanner that is defined as appropriate. See chapter "Appropriate Use".

● The ambient and operating conditions given in the available applicationdocumentation must be observed.

● Applications for functional safety are only allowed if clearly and explicitlyspecified in the application documentation "Integrated Safety Technolo‐gy". If this is not the case, they are excluded. Functional safety is a safe‐ty concept in which measures of risk reduction for personal safety de‐pend on electrical, electronic or programmable control systems.

● The information given in the application documentation with regard tothe use of the delivered components contains only examples of applica‐tions and suggestions.The machine and installation manufacturers must– make sure that the delivered components are suited for their indi‐

vidual application and check the information given in this applica‐tion documentation with regard to the use of the components,

– make sure that their individual application complies with the appli‐cable safety regulations and standards and carry out the requiredmeasures, modifications and complements.

● Commissioning of the delivered components is only allowed once it issure that the machine or installation in which the components are instal‐led complies with the national regulations, safety specifications andstandards of the application.

● Operation is only allowed if the national EMC regulations for the applica‐tion are met.

● The instructions for installation in accordance with EMC requirementscan be found in the section on EMC in the respective application docu‐mentation.The machine or installation manufacturer is responsible for compliancewith the limit values as prescribed in the national regulations.

● The technical data, connection and installation conditions of the compo‐nents are specified in the respective application documentations andmust be followed at all times.

National regulations which the user has to comply with● European countries: In accordance with European EN standards● United States of America (USA):

– National Electrical Code (NEC)– National Electrical Manufacturers Association (NEMA), as well as

local engineering regulations– Regulations of the National Fire Protection Association (NFPA)

● Canada: Canadian Standards Association (CSA)● Other countries:

– International Organization for Standardization (ISO)– International Electrotechnical Commission (IEC)

3.2.3 Hazards by improper use● High electrical voltage and high working current! Danger to life or seri‐

ous injury by electric shock!




● High electrical voltage by incorrect connection! Danger to life or injury byelectric shock!

● Dangerous movements! Danger to life, serious injury or property dam‐age by unintended motor movements!

● Health hazard for persons with heart pacemakers, metal implants andhearing aids in proximity to electric drive systems!

● Risk of burns by hot housing surfaces!● Risk of injury by improper handling! Injury by crushing, shearing, cutting,

hitting!● Risk of injury by improper handling of batteries!● Risk of injury by improper handling of pressurized lines!

3.3 Instructions with regard to specific dangers3.3.1 Protection against contact with electrical parts and housings

This section concerns components of the electric drive and con‐trol system with voltages of more than 50 volts.

Contact with parts conducting voltages above 50 volts can cause personaldanger and electric shock. When operating components of the electric driveand control system, it is unavoidable that some parts of these componentsconduct dangerous voltage. High electrical voltage! Danger to life, risk of injury by electric shock or seri‐ous injury!● Only qualified persons are allowed to operate, maintain and/or repair the

components of the electric drive and control system.● Follow the general installation and safety regulations when working on

power installations.● Before switching on, the equipment grounding conductor must have

been permanently connected to all electric components in accordancewith the connection diagram.

● Even for brief measurements or tests, operation is only allowed if theequipment grounding conductor has been permanently connected to thepoints of the components provided for this purpose.

● Before accessing electrical parts with voltage potentials higher than50 V, you must disconnect electric components from the mains or fromthe power supply unit. Secure the electric component from reconnec‐tion.

● With electric components, observe the following aspects:Always wait 30 minutes after switching off power to allow live capacitorsto discharge before accessing an electric component. Measure the elec‐trical voltage of live parts before beginning to work to make sure that theequipment is safe to touch.

● Install the covers and guards provided for this purpose before switchingon.

● Never touch any electrical connection points of the components whilepower is turned on.

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● Do not remove or plug in connectors when the component has beenpowered.

● Under specific conditions, electric drive systems can be operated atmains protected by residual-current-operated circuit-breakers sensitiveto universal current (RCDs/RCMs).

● Secure built-in devices from penetrating foreign objects and water, aswell as from direct contact, by providing an external housing, for exam‐ple a control cabinet.

High housing voltage and high leakage current! Danger to life, risk of injuryby electric shock!● Before switching on and before commissioning, ground or connect the

components of the electric drive and control system to the equipmentgrounding conductor at the grounding points.

● Connect the equipment grounding conductor of the components of theelectric drive and control system permanently to the main power supplyat all times. The leakage current is greater than 3.5 mA.

● Establish an equipment grounding connection with a minimum crosssection according to the table below. With an outer conductor cross sec‐tion smaller than 10 mm2 (8 AWG), the alternative connection of twoequipment grounding conductors is allowed, each having the samecross section as the outer conductors.

Cross section outer con‐ductor

Minimum cross section equipment grounding conductorLeakage current ≥ 3.5 mA

1 equipment groundingconductor

2 equipment groundingconductors

1.5 mm2 (16 AWG)

10 mm2 (8 AWG)

2 × 1.5 mm2 (16 AWG)

2.5 mm2 (14 AWG) 2 × 2.5 mm2 (14 AWG)

4 mm2 (12 AWG) 2 × 4 mm2 (12 AWG)

6 mm2 (10 AWG) 2 × 6 mm2 (10 AWG)

10 mm2 (8 AWG) -

16 mm2 (6 AWG)

16 mm2 (6 AWG)

-

25 mm2 (4 AWG) -

35 mm2 (2 AWG) -

50 mm2 (1/0 AWG) 25 mm2 (4 AWG) -

70 mm2 (2/0 AWG) 35 mm2 (2 AWG) -

... ... ...

Tab. 3-1: Minimum cross section of the equipment grounding connection

3.3.2 Protective extra-low voltage as protection against electric shock Protective extra-low voltage is used to allow connecting devices with basic in‐sulation to extra-low voltage circuits.On components of an electric drive and control system provided by BoschRexroth, all connections and terminals with voltages up to 50 volts are PELV




("Protective Extra-Low Voltage") systems. It is allowed to connect devicesequipped with basic insulation (such as programming devices, PCs, note‐books, display units) to these connections. Danger to life, risk of injury by electric shock! High electrical voltage by incor‐rect connection!If extra-low voltage circuits of devices containing voltages and circuits ofmore than 50 volts (e.g., the mains connection) are connected to BoschRexroth products, the connected extra-low voltage circuits must comply withthe requirements for PELV ("Protective Extra-Low Voltage").

3.3.3 Protection against dangerous movementsDangerous movements can be caused by faulty control of connected motors.Some common examples are:● Improper or wrong wiring or cable connection● Operator errors● Wrong input of parameters before commissioning● Malfunction of sensors and encoders● Defective components● Software or firmware errorsThese errors can occur immediately after equipment is switched on or evenafter an unspecified time of trouble-free operation.The monitoring functions in the components of the electric drive and controlsystem will normally be sufficient to avoid malfunction in the connecteddrives. Regarding personal safety, especially the danger of injury and/orproperty damage, this alone cannot be relied upon to ensure complete safety.Until the integrated monitoring functions become effective, it must be as‐sumed in any case that faulty drive movements will occur. The extent of faultydrive movements depends upon the type of control and the state of opera‐tion. Dangerous movements! Danger to life, risk of injury, serious injury or propertydamage!A risk assessment must be prepared for the installation or machine, with itsspecific conditions, in which the components of the electric drive and controlsystem are installed.As a result of the risk assessment, the user must provide for monitoring func‐tions and higher-level measures on the installation side for personal safety.The safety regulations applicable to the installation or machine must be takeninto consideration. Unintended machine movements or other malfunctionsare possible if safety devices are disabled, bypassed or not activated.To avoid accidents, injury and/or property damage:● Keep free and clear of the machine’s range of motion and moving ma‐

chine parts. Prevent personnel from accidentally entering the machine’srange of motion by using, for example:– Safety fences– Safety guards– Protective coverings– Light barriers

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● Make sure the safety fences and protective coverings are strong enoughto resist maximum possible kinetic energy.

● Mount emergency stopping switches in the immediate reach of the oper‐ator. Before commissioning, verify that the emergency stopping equip‐ment works. Do not operate the machine if the emergency stoppingswitch is not working.

● Prevent unintended start-up. Isolate the drive power connection bymeans of OFF switches/OFF buttons or use a safe starting lockout.

● Make sure that the drives are brought to safe standstill before accessingor entering the danger zone.

● Additionally secure vertical axes against falling or dropping after switch‐ing off the motor power by, for example,– mechanically securing the vertical axes,– adding an external braking/arrester/clamping mechanism or– ensuring sufficient counterbalancing of the vertical axes.

● The standard equipment motor holding brake or an external holdingbrake controlled by the drive controller is not sufficient to guarantee per‐sonal safety!

● Disconnect electrical power to the components of the electric drive andcontrol system using the master switch and secure them from reconnec‐tion ("lock out") for:– Maintenance and repair work– Cleaning of equipment– Long periods of discontinued equipment use

● Prevent the operation of high-frequency, remote control and radio equip‐ment near components of the electric drive and control system and theirsupply leads. If the use of these devices cannot be avoided, check themachine or installation, at initial commissioning of the electric drive andcontrol system, for possible malfunctions when operating such high-fre‐quency, remote control and radio equipment in its possible positions ofnormal use. It might possibly be necessary to perform a special electro‐magnetic compatibility (EMC) test.

3.3.4 Protection against electromagnetic and magnetic fields during opera‐tion and mounting

Electromagnetic and magnetic fields!Health hazard for persons with active implantable medical devices (AIMD)such as pacemakers or passive metallic implants.● Hazards for the above-mentioned groups of persons by electromagnetic

and magnetic fields in the immediate vicinity of drive controllers and theassociated current-carrying conductors.

● Entering these areas can pose an increased risk to the above-men‐tioned groups of persons. They should seek advice from their physician.

● If overcome by possible effects on above-mentioned persons during op‐eration of drive controllers and accessories, remove the exposed per‐sons from the vicinity of conductors and devices.




3.3.5 Protection against contact with hot partsHot surfaces of components of the electric drive and control system. Risk ofburns!● Do not touch hot surfaces of, for example, braking resistors, heat sinks,

supply units and drive controllers, motors, windings and laminatedcores!

● According to the operating conditions, temperatures of the surfaces canbe higher than 60 °C (140 °F) during or after operation.

● Before touching motors after having switched them off, let them cooldown for a sufficient period of time. Cooling down can require up to 140minutes! The time required for cooling down is approximately five timesthe thermal time constant specified in the technical data.

● After switching chokes, supply units and drive controllers off, wait 15 mi‐nutes to allow them to cool down before touching them.

● Wear safety gloves or do not work at hot surfaces.● For certain applications, and in accordance with the respective safety

regulations, the manufacturer of the machine or installation must takemeasures to avoid injuries caused by burns in the final application.These measures can be, for example: Warnings at the machine or in‐stallation, guards (shieldings or barriers) or safety instructions in the ap‐plication documentation.

3.3.6 Protection during handling and mountingRisk of injury by improper handling! Injury by crushing, shearing, cutting, hit‐ting!● Observe the relevant statutory regulations of accident prevention.● Use suitable equipment for mounting and transport.● Avoid jamming and crushing by appropriate measures.● Always use suitable tools. Use special tools if specified.● Use lifting equipment and tools in the correct manner.● Use suitable protective equipment (hard hat, safety goggles, safety

shoes, safety gloves, for example).● Do not stand under hanging loads.● Immediately clean up any spilled liquids from the floor due to the risk of

falling!

3.3.7 Battery safetyBatteries consist of active chemicals in a solid housing. Therefore, improperhandling can cause injury or property damage.Risk of injury by improper handling!● Do not attempt to reactivate low batteries by heating or other methods

(risk of explosion and cauterization).● Do not attempt to recharge the batteries as this may cause leakage or

explosion.● Do not throw batteries into open flames.● Do not dismantle batteries.

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● When replacing the battery/batteries, do not damage the electrical partsinstalled in the devices.

● Only use the battery types specified for the product.

Environmental protection and disposal! The batteries contained inthe product are considered dangerous goods during land, air, andsea transport (risk of explosion) in the sense of the legal regula‐tions. Dispose of used batteries separately from other waste. Ob‐serve the national regulations of your country.

3.3.8 Protection against pressurized systemsAccording to the information given in the Project Planning Manuals, motorsand components cooled with liquids and compressed air can be partially sup‐plied with externally fed, pressurized media, such as compressed air, hy‐draulics oil, cooling liquids and cooling lubricants. Improper handling of theconnected supply systems, supply lines or connections can cause injuries orproperty damage.Risk of injury by improper handling of pressurized lines!● Do not attempt to disconnect, open or cut pressurized lines (risk of ex‐

plosion).● Observe the respective manufacturer's operating instructions.● Before dismounting lines, relieve pressure and empty medium.● Use suitable protective equipment (safety goggles, safety shoes, safety

gloves, for example).● Immediately clean up any spilled liquids from the floor due to the risk of

falling!

Environmental protection and disposal! The agents (e.g., fluids)used to operate the product might not be environmentally friendly.Dispose of agents harmful to the environment separately fromother waste. Observe the national regulations of your country.




3.4 Explanation of signal words and the Safety alert symbolThe Safety Instructions in the available application documentation containspecific signal words (DANGER, WARNING, CAUTION or NOTICE) and,where required, a safety alert symbol (in accordance with ANSIZ535.6-2011).The signal word is meant to draw the reader's attention to the safety instruc‐tion and identifies the hazard severity.The safety alert symbol (a triangle with an exclamation point), which pre‐cedes the signal words DANGER, WARNING and CAUTION, is used to alertthe reader to personal injury hazards.

DANGER

In case of non-compliance with this safety instruction, death or serious injurywill occur.

WARNING

In case of non-compliance with this safety instruction, death or serious injurycould occur.

CAUTION

In case of non-compliance with this safety instruction, minor or moderate in‐jury could occur.

NOTICE

In case of non-compliance with this safety instruction, property damage couldoccur.

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4 Technical data4.1 Explanations about technical data4.1.1 Introduction

All relevant technical motor data as well as the functional principle of this mo‐tors are provided on the following pages in terms of tables and characteristiccurves. The following dependencies are taken into consideration:● Frame size and frame length of the primary part● Winding design primary part● Available power connection or DC bus voltage

All specified data and characteristic curves refer to the followingconditions, unless otherwise specified:● Self-cooling● Installation mode B acc. to Tab. 9-12 on page 131● Keeping installation tolerances acc. tochapter 5.1 "Specifi‐

cations" on page 45● Keeping ambient temperatures acc. to chapter 9.3 "Installa‐

tion altitude and ambient conditions" on page 100● Motor winding temperature ≤110 °C

Specified values in the data sheet are effective values accordingto DIN EN 60034-1. The reference value is a maximum DC busvoltage of 300 VDC at MCP020 ... 070 or 48VDC for MCP015. Re‐sulting data from special motor-controller combinations may differfrom this specified data.

All relationships and data described in the following sections mayonly apply if exclusively primary and secondary parts of the samesize are combined (e.g. MCP015 with MCS015).

4.1.2 Operating behaviorThe characteristic curve “force over speed” is specified as a characteristiccurve The basic parameters and the run of the characteristic curve is definedby the height of the intermediate circuit voltage and by the corresponding mo‐tor specific data, like e.g. inductivity, resistance, force constant and so on. Byvarying the intermediate circuit voltage (different controllers or supply mod‐ules and connection voltages) and different motor windings result in differentcharacteristics result.Furthermore, a continuous force characteristic curve FN for installation modeB (good thermal connection) is shown. The installation modes are describedin Chapter 9.22 .


Technical data


Fmax Maximum forceFN Continuous nominal forceFN* To avoid damaged winding in standstill operation, limit the cur‐

rent or the operation duration.vFmax Maximum velocity at maximum forcevN Nominal velocityvmax Maximum velocityUN DC bus voltage 300 VDC① When using the motor in this operating range, observe informa‐

tion specified in chapter 9.23 .Fig. 4-1: Example motor characteristic curve

For deviating connection or DC bus voltages, the specified char‐acteristic curves can be converted – in linear form – according tothe existing voltages.

The maximal force Fmax is available up to speed vFmax. There, the specifiedvoltage limit is reached due to the DC bus voltage. However, during increas‐ing velocity, the induced voltage of the motor increases. This leads to a ve‐locity-dependend reduced maximum force, as the motor control voltage willbe reduced due to the constant DC bus voltage.The continuous nominal force FN is available up to nominal velocity vN.The maximum velocity vmax is the maximum reachable motor velocity at ap‐propriate UDC up to approximately FN = 0 N.

The reachable motor data are significantly dependent from thethermal coupling of the motor onto the machine (power loss dissi‐pation) and from the used drive controller. The reference quantityfor details of technical data and the presentation of the motorcharacteristic curves is an uncontrolled DC bus voltage of 300VDC from MCP020 up to MCP070 or 48 VDC for MCP015.You will find additional notes about thermal coupling under Chap‐ter 9.22 .Notes about standstill operation in Chapter 9.23 .

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Technical data



Parallel operation of two primaryparts on a drive controller It is only allowed to connect primary parts parallel, which features

are identical. Usually this is only the case with identically con‐structed types.

In the following is spoken of “identical” primary parts.● Same force constant KFN or voltage constant KEMK

● Same winding resistance R12

● Same winding inductivity L12

The following interrelations exist for the parallel connection of two identicalprimary parts at one drive controller (see Fig. 4-2):● Doublication of the feed force of the axis in the case of same current in

each primary part (it not limited by the drive controller).Ftotal = 2 x FMotor

● Doublication of the voltage within the drive controller (if not limited by it)IInverter = 2 x IMotor

● Velocity vFmax, vN and vmax as for single arrangementvFmax,total = vFmax,Motor / vN,total = vN,Motor / vmax,total = vmax,Motor

● Same motor and voltage constant (KFN, KEMK)KFN,total = KFN,Motor / KEMK,total = KEMK,Motor

● Total motor resistance and inductivity halvedR12,total = 1/2 x R12,Motor / L12,total = 1/2 x L12,Motor

A Single arrangementB Parallel arrangementFig. 4-2: Characteristics force over velocity at single or parallel arrangment of

two primary parts on one controller


Technical data


For parallel connection of two primary parts at one drive control‐ler, relevant motor parameters for start-up are specified in thisdocumentation (see Kapitel 14.4.3 on page 170).

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Technical data



4.1.3 Description of specified sizes

The PWM-Frequency of the drive controller affects the resultingmotor data. All data in this documentation refer to a PWM-Fre‐quency of 4 kHz.

Characteristics for primary parts MCL

Designation Symbol Unit Toler‐ance Description

Maximum force Fmax N ± 5 % Maximum force at maximum current Imax. The force that can be reacheddepends on the drive control device used.

Continuous nominal force FN N ± 5 % Available continuous nominal force of the motor up to vN at nominal cur‐rent IN.

Maximum current Imax A Maximum current of the motor at Fmax.

Rated current IN A Rated current of the motor at continuous nominal force FN.

Reference voltage DC busvoltage UDC V Reference voltage of intermediate circuit for determination of the winding

velocity.

Maximum velocity at Fmax vFmax m/min Maximum velocity at maximum force Fmax. The velocity reached dependson the DC bus voltage of the used drive control device.

Nominal velocity vN m/min Velocity, up to continuous nominal force FN of the motor is available.

Force constant KFN N/A ± 5 %Relation of force increase to increase of force-creating current. Due to theprinciple of an ironless primary part, no saturation effects occur. There‐with, the constant is not current-dependent.

Voltage constant at 20 °C KEMK Vs/m ± 5 % Induced motor voltage depending from the travel velocity relating on ve‐locity 1 m/s at 20°C.

Winding resistance at 20 °C R12 Ω Measured winding resistance among two strands at 20 °C.

Winding inductivity L12 mH Measured winding inductivity between two strands. The defined measur‐ing values are fluctuating due to boundary effects. These details are typi‐cal values, which are determined with a measuring current of 1 mA at ameasuring frequency of 1 kHz.

Winding inductivity L23/31 mH Measured winding inductivity among two strands (strand 2/3 or 3/1). Dueto fringe effects, the specified measured values are different to L12. Thesedetails are typical values, which are determined with a measuring currentof 1 mA at a measuring frequency of 1 kHz.

Rated power loss PVN W Power loss in operation mode S1 (continuous operation) at nominal veloc‐ity vN.

Pole width τP mm Distance dimension of pole center to pole center of the magnets on thesecondary part.

Thermal time constant Tth

Duration of temperature rise to 63% of the final temperature of the wind‐ing at natural convection and load with continuous nominal force in S1-op‐eration.

① Chronological course of the winding temperatureθmax Max. winding temperatureTth Thermal time constantFig. 4-3: Thermal time constant

Mass primary part mP kg Mass of primary part


Technical data


Characteristics for secondary parts MCS

Designation Symbol Unit Toler‐ance Description

Mass secondary partmS kg Mass secondary part mS.

mS_rel kg/m Relative mass of the secondary part relating on 1 m length.

4.2 IndraSizeBy using the IndraSize software, drive controllers, motors and mechanicgearboxes can be easily sized. The engineering tool covers the entire rangeof Rexroth drives and motors. Calculate the characteristic curves for your ap‐plication by using the sizing and calculation tool IndraSize: www.boschrex‐roth.com/IndraSize

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Technical data



https://www.boschrexroth.com/en/xc/products/product-support/econfigurators-and-tools/indrasize/indrasize-2

https://www.boschrexroth.com/en/xc/products/product-support/econfigurators-and-tools/indrasize/indrasize-2

4.3 General technical dataThe data specified in Tab. apply for all motor sizes. In this context, however,the comments on the individual items in Chapter “Application notes” must beobserved.

Designation Symbol Unit MCPxxx MCSxxx

Maximum allowed DC bus voltage MCP015UDC, max V

72/Maximum allowed DC bus voltage MCP020 ...

070 420

Ambient temperature in operation(see also chapter 9.3 "Installation altitude andambient conditions" on page 100)

Tamb °C 0 ... +40

Allowed transport temperature(see also chapter 12.3.1 "Notes about trans‐port" on page 156)

TT °C -20 ... +80

Allowed storage temperature(see also chapter 12.3.2 "Information on stor‐age" on page 157)

TL °C -25 ... +55

Thermal class acc. to DIN EN 60034-1 - - 130 (B) /

Warning temperature (winding)(See auch chapter 9.10 "Motor temperaturemonitoring" on page 107)

Twarn °C 110 /

Shutdown temperature (winding)(see also chapter 9.10 "Motor temperaturemonitoring" on page 107)

Tabst °C 130 /

Degree of protection MCP and MCS accordingto DIN EN 60034-5 - -

IP00(IP20 for front surface of MCP020 ... 070)

RoHS conformity according to EC guidelines2011/65/EG - - RoHS conform

Latest amendment: 2019-12-16

Tab. 4-1: General technical data


Technical data


4.4 Frame size 0154.4.1 Data sheet MCP015

Designation Symbol Unit

MCP015

A B

L040 L040

Maximum force Fmax N 36 72

Continuous nominal force FN N 9 18

Maximum current Imax A 6.0 12.8

Rated current IN A 1.5 3.2

Reference voltage DC bus voltage UDC V 48

Maximum velocity at Fmax vFmax m/min 0

Nominal velocity vN m/min 430 480

Force constant KFN N/A 6.0 5.6

Voltage constant at 20 °C KEMK Vs/m 3.6 3.2

Winding resistance at 20 °C R12 Ohm 5.3 2.7

Winding inductance L12 mH 0.56 0.25

Winding inductivity L23, 31 mH 0.56 0.25

Rated power loss PVN W 23.9 55.2

Pole width τp mm 8.25

Thermal time constant Tth min 0.6

Primary part mass mP kg 0.050 0.075


Tab. 4-2: MCP015 - Technical data

4.4.2 Data sheet MCS015

Designation Symbol Unit MCS015-__-0066 MCS015-__-0099

Secondary part mass mS kg 0.2 0.3

Mass secondary part, relative mS_rel kg/m 3.0


Tab. 4-3: MCS015 - Technical data

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Technical data



4.4.3 Motor characteristic curve frame size 015

Fig. 4-4: Motor characteristic curve MCP015A-L040 at 48 VDC

Fig. 4-5: Motor characteristic curve MCP015B-L040 at 48 VDC


Technical data




MCP020

B C D

V180 V720 V180 V720 V180 V720

Maximum force Fmax N 104 156 208

Continuous nominal force FN N 26 39 52

Maximum current Imax A 3.2 5.6 4.9 8.8 7.0 13.0

Rated current IN A 0.8 1.4 1.2 2.2 1.7 3.2


Maximum velocity at Fmax vFmax m/min 200 690 160 660 220 820

Nominal velocity vN m/min 560 1100 550 1095 620 1260

Force constant KFN N/A 32.5 18.6 32.0 17.8 30.1 16.0

Voltage constant at 20 °C KEMK Vs/m 18.8 10.7 18.5 10.3 17.4 9.2

Winding resistance at 20 °C R12 Ohm 40.5 13.3 28 8.8 18 5.5

Winding inductivity L12 mH 4.4 1.5 2.9 0.9 1.9 0.6

Winding inductivity L23, 31 mH 6.6 2.2 4.3 1.3 2.7 0.9

Rated power loss PVN W 51.8 52.1 94.5 85.1 129.8 134.6

Pole width τp mm 15

Thermal time constant Tth min 1.7 1.9 2.1

Primary part mass mP kg 0.18 0.28 0.38




Designation Symbol Unit MCS020-__-0120 MCS020-__-0180 MCS020-__-0300

Secondary part mass mS kg 0.4 0.7 1.1




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Technical data



4.5.3 Motor characteristic curves frame size 020

Fig. 4-6: Motor characteristic curves MCP020B at 300 VDC

Fig. 4-7: Motor characteristic curves MCP020C at 300 VDC


Technical data


Fig. 4-8: Motor characteristic curves MCP020D at 300 VDC

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Technical data



4.6 Frame size 0304.6.1 Data Sheet MCP030


MCP030

B C D

V180 V390 V180 V390 V180 V390

Maximum force Fmax N 192 296 420

Continuous nominal force FN N 48 74 105

Maximum current Imax A 5.2 6.4 7.2 9.6 10.0 14.0

Rated current IN A 1.3 1.6 1.8 2.4 2.5 3.5


Maximum velocity at Fmax vFmax m/min 180 400 170 370 180 380

Nominal velocity vN m/min 510 680 460 630 440 660

Force constant KFN N/A 36.9 30.0 41.1 30.8 42.0 30.0

Voltage constant at 20 °C KEMK Vs/m 21.3 17.3 23.7 17.8 24.2 17.3

Winding resistance at 20 °C R12 Ohm 27 14.6 20 10.6 14 7.9

Winding inductivity L12 mH 10.1 5.6 7.5 4.19 5.56 2.9

Winding inductivity L23, 31 mH 16.2 9.1 11.6 6.16 8.17 4.7

Rated power loss PVN W 91.1 74.6 129.4 121.9 174.8 193.3



Primary part mass mP kg 0.34 0.52 0.70










Technical data



Fig. 4-9: Motor characteristic curve MCP030B at 300 VDC

Fig. 4-10: Motor characteristic curve MCP030C at 300 VDC

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Technical data



Fig. 4-11: Motor characteristic curve MCP030D at 300 VDC


Technical data




MCP040

B C

V070 V300 V070 V300



Maximum current Imax A 4.8 7.6 6.8 11.6

Rated current IN A 1.2 1.9 1.7 2.9


Maximum velocity at Fmax vFmax m/min 80 290 60 310

Nominal velocity vN m/min 290 530 290 530

Force constant KFN N/A 60.8 38.4 63.5 37.2

Voltage constant at 20 °C KEMK Vs/m 35.1 22.2 36.7 21.5

Winding resistance at 20 °C R12 Ohm 30 11.4 22 7.4

Winding inductivity L12 mH 14.6 5.6 10.8 3.7

Winding inductivity L23, 31 mH 22.6 8.9 15.9 5.6

Rated power loss PVN W 86.3 82.2 127.0 124.3


Thermal time constant Tth min 2.3 2.4



Tab. 4-8: MCP040B/C - Technical data


MCP040

E G

V070 V300 V070 V300









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Technical data




MCP040

E G

V070 V300 V070 V300



Winding resistance at 20 °C R12 Ohm 12.7 5 9.7 3.3

Winding inductance L12 mH 6.4 2.4 4.8 1.6

Winding inductivity L23, 31 mH 9.5 3.5 7 2.4






Tab. 4-9: MCP040E/G - Technical data







4.7.3 Motor characteristic curves frame size 040

Fig. 4-12: Motor characteristic curve MCP040B at 300 VDC


Technical data



Fig. 4-14: Motor characteristic curve MCP040E at 300 VDC

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Technical data



Fig. 4-15: Motor characteristic curve MCP040G at 300 VDC


Technical data




MCP070

C D

V050 V300 V050 V300










Winding resistance at 20 °C R12 Ohm 15.7 3.03 13.2 2.94

Winding inductivity L12 mH 12 2.3 10 2







Tab. 4-11: MCP070C/D - Technical data


MCP070

F M

V050 V300 V050 V230



Maximum current Imax A 18.4 36.0 62.8

Rated current IN A 4.6 9.0 15.7





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Technical data




MCP070

F M

V050 V300 V050 V230



Winding resistance at 20 °C R12 Ohm 7.5 2.2 3.8 1.25

Winding inductivity L12 mH 5.7 1.39 2.66 0.92







Tab. 4-12: MCP070F/M - Technical data










Technical data


Fig. 4-17: Motor characteristic curve MCP070D at 300 VDC

Fig. 4-18: Motor characteristic curve MCP070F at 300 VDC

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Technical data



Fig. 4-19: Motor characteristic curve MCP070M at 300 VDC


Technical data


5 Dimension sheets5.1 Specifications

Comply with the trademark rights of third parties during assemblyand use of single components delivered by Bosch Rexroth. Forany infringement of the right, the customer is liable for the accru‐ing damage.

5.1.1 Air gap and installation heightTo ensure safe operation and constant force over the entire travel range, anair gap is required between primary and secondary part. For this purpose, theindividual parts of the motor are tolerated accordingly. The distance of themounting surface, the parallelism and the symmetry of the primary and sec‐ondary part of the linear motor in the machine must be within a certain toler‐ance above the entire travel length. Any deformations that result from weight,attractive forces and process forces must be taken into account.

● The specified installation dimensions with respective toleran‐ces must always be complied with over the entire travellength. An insufficient air gap may lead to contact betweenthe primary part and the secondary part and thus to dam‐aged and destroyed motor components.

● Long distances can make is necessary that the contact sur‐faces of the motor components must be directly processedfrom the mounted slide.

For the installation of the motors into the machine structure, Bosch Rexrothspecifies a defined installation position with tolerances. Thus, the specifiedsize and tolerances of the air gap are maintained automatically – even if indi‐vidual motor components are replaced.


Dimension sheets


5.1.2 Installation dimensions MCL015

Frame size

Motor height Motor width

MCL MCP MCS

A B C

015 51 mm 13.5 mm 14.8 mm

For tolerance details refer to the dimension sheetTab. 5-1: MCL015 Installation dimensions and tolerances

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Dimension sheets



5.1.3 Installation dimensions MCL020 ... 070

Size

Motor height Motor width

MCL MCP MCS

A B C

020 52.0 mm 20.5 mm 20.8 mm

030 67.0 mm 24.7 mm 25.0 mm

040 86.4 mm 34.0 mm 34.3 mm

070 124.0 mm 49.2 mm 49.5 mm

For tolerance details refer to the dimension sheetTab. 5-2: Installation dimensions and tolerances MCL020 ... 070

The specified installation dimensions with respective tolerancesmust always be complied with over the entire travel length.


Dimension sheets


5.1.4 Parallelism and symmetry of machine partsBefore primary and secondary part can be mounted, align the parts of themachine. Especially the machine slide is to be brought into a defined positionto the machine bed. When aligning, the installation dimensions and toleran‐ces regarding parallelism and symmetry must be kept.To keep the tolerances, it is necessary that the fastening holes for the pri‐mary part and the threaded holes for the primary and secondary part in themachine are strictly realized according to the dimensions of the particular di‐mension sheets. The alignment of the motor components must be done ac‐cording to Fig. 5-1.You will find further notes regarding assembly of primary and secondary partsin chapter 13 on page 159.

① Secondary part② Primary partFig. 5-1: Parallelism and symmetry between primary part and secondary part

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Dimension sheets




Dimension sheets


5.2 Dimensional sheets for MCL015

Fig. 5-2: Dimensional sheets primary part MCP015

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Dimension sheets



Fig. 5-3: Dimensional sheets secondary part MCS015


Dimension sheets


5.3 Dimensional sheets MCL020


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Dimension sheets





Dimension sheets


5.4 Dimensional sheets for MCL030


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Dimension sheets





Dimension sheets




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Dimension sheets





Dimension sheets




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Dimension sheets





Dimension sheets


6 Identification6.1 Type codes 6.1.1 General

The type code describes the deliverable motor variants. It is the basis for se‐lecting and ordering products from Bosch Rexroth. This applies to new prod‐ucts as well as to spare parts and repairs..Based on an exemplary motor, type codes are listed by which an exact deter‐mination of the single components (e.g. for orders) is possible.The following description gives an overview over the separate columns of thetype code (”abbrev. column”) and its meaning.

When selecting a product, always consider the detailed specifica‐tions in chapter 4 "Technical data" on page 21 and chapter 9 "Application and construction instructions" on page 97.

6.1.2 Type codes primary part MCPGeneral

Fig. 6-1: Example - type code primary part MCP040


Identification


ProductAbbrev. column 1 2 3 MCP is the designation of the primary part of an ironless linear motors.

Frame sizeAbbrev. column 4 5 6 The motor frame size is derived from the active motor length and represents

different power ranges.

Frame lengthsAbbrev. column 7 Within a series, increasing motor frame length is graded by means of code

letters.

WindingAbbrev. column 9 10 11 12 The specified winding designation is done via a preceeded “V” for a DC bus

voltage of 300 VDC, with a preceeded “L” for a DC bus voltage of 48 VDC.

CoolingAbbrev. column 14 MCP primary parts are only available with self cooling.

Frame shapeAbbrev. column 15 Two different frame sizes are available, depending from the frame size. The

frame size is derived from the cross section of the respective primary partand is described by the letters “T” and “I”.

Hall unitAbbrev. column 17 18 Primary parts in frame sizes 020 up to 070 can be optionally fitted with a Hall

unit for position acquisition. Depended from the frame size, the following Hallunits with different output signals are available:● L1 = analog● L0 = digital● N0 = noneThe cable output direction of the Hall unit is done to the same front side asfor the power connection.The necessary length measuring system is not in the scope of delivery ofBosch Rexroth and must be provided and mounted by the machine manufac‐turer.

Electrical connectionShort-text column 19 20 All primary parts are fitted with a flexible and shielded connection cable. The

connection cable is fixed with the primary part and is done at the front side atMCP020 up to MCP070, laterally for the MCP015.

Other designsAbbrev. column 22 23 24 25 NNNN = no other design.

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Identification



6.1.3 Type code MCS secondary partGeneral

Fig. 6-2: Example - type code secondary part MCS040

ProductAbbrev. column 1 2 3 MCS is the designation of the secondary part of an ironless linear motor.

Frame sizeAbbrev. column 4 5 6 The frame size of the secondary part is derived from the active motor length

and represents different power ranges.

Mechanical designAbbrev. column 8 The number 3 stands for fastening of the secondary part with screws.

Mechanical protectionAbbrev. column 9 To ensure the optimal operation reliability, the permanent magnets of the

secondary part are protected against outside influences like corrosion bycoating. Hence, no additional cover is necessary for this specified environ‐mental conditions.

Segment lengthsAbbrev. column 11 12 13 14 Depending from the motor frame size, different secondary part lengths are

available.

Other designsAbbrev. column 16 17 18 19 NNNN = no other design.


Identification


6.1.4 Type code frame size 015

Fig. 6-3: Type code primary part MCP015

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Identification



Fig. 6-4: Type code secondary part MCS015


Identification




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Identification





Identification




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Identification





Identification




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Identification





Identification




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Identification





Identification


6.2 Identification6.2.1 Identification MCP primary part

An engraved type designation is on the primary part.

① Type designation (not for MCP015)② Serial numberFig. 6-13: Position of type designation and serial number of primary partAdditionally, the primary part has two identical type plates at delivery. Thetype plates allow an univocal identification of the primary part and can befixed on the machine or used be used elsewhere by the user.

1 Motor type2 Type designation3 Designation of origin4 Factory number5 Mass of primary part6 EC declaration of conformity7 Rated power8 Maximum input voltage9 Company address10 Insulation system11 Thermal class12 Degree of protection by housing13 Manufacturing date14 Pole pitch15 Rated current16 Serial number17 Change status18 Rexroth barcode19 Material number20 China RoHS conformity markFig. 6-14: Type plate example primary part

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Identification



6.2.2 Identification MCS secondary partThe type designation with serial number is at the bottom of the secondarypart.

① Type designation② Serial numberFig. 6-15: Position of type designation and serial number of secondary partAdditionally, the secondary part has two identical type plates at delivery. Thetype plates allow an univocal identification of the secondary part and can befixed on the machine or used be used elsewhere by the user.

1 Motor type2 Type designation3 Designation of origin4 Factory number5 Mass secondary part6 EC declaration of conformity7 Maximum input voltage8 Company address9 Thermal class10 Degree of protection by housing11 Manufacturing date12 Serial number13 Change status14 Rexroth barcode15 Material number16 China RoHS conformity markFig. 6-16: Type plate example secondary part


Identification


6.2.3 Certification markCertification mark Significance

Conformity with applicable EC Directives

EAC stands for Eurasian Conformity.

25 Conformity according to RoHS and China RoHS2.

Tab. 6-1: Certification mark at type plate

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Identification



7 Accessories and options7.1 Hall unit7.1.1 General

For control of synchronous motors, the absolute position information regard‐ing a pole pair is required to recognize the position of the permanent magnetsto the motor windings. Only in connection with an electrical commutation off‐set angle to be determined on initial commissioning, the current with correctphase position to the magnetic field can be set via the controller to enablegeneration of a defined force in the dedicated travel direction by the motor.If an incremental length measuring system is used, commutation of the axishas to be performed every time the phase of the drive is step up. This is real‐ized by a drive-internal procedure. Subsequently, the motor power can devel‐op.

The commutation is determined automatically during the phasestep up by the Hall unit. Therefore, no power switch-on is neces‐sary (no motor movement).

The Hall unit offers special advantages, for commutation of linear motors, forexample ...● in gantry arrangement ● at vertical axes● in mechanically secured state,● that must not be moved for safety reasons during commutation.

7.1.2 Hall unit functionThe Hall unit (analog or digital) serves for motionless commutation of the line‐ar motor in connection with an incremental measuring system. For IndraDriveCs, the motor commutation is performed automatically on phase switching tooperating mode. For this, motion is not required. The motor may also be in afixed stop or positioned at the end of the travel length (end stop), for exam‐ple.Rexroth linear motors of MCL020 ... 070 series can be ordered according tothe motor type code with or without Hall unit (seechapter 6.1.2 "Type codesprimary part MCP" on page 61).

Independent from the origin order, primary parts of frame size020 ... 070 can be converted or upgraded with a separately order‐able Hall unit.


Accessories and options


Hall unit analog Analog Hall units for MCL of Rexroth create two sinusoidal signals, with aphase offset of 120°. The output voltage is 1 VSS dependend from the posi‐tion of the Hall unit over the magnets of the secondary part and is provided atthe lines according to 7-1 The voltage supply is 7 ... 20V. A minimum currentconsumption of 40 mA to the Hall unit must be ensured.

Fig. 7-1: Signal process of an analog Hall unit

Bosch Rexroth controllers use a supply voltage of 12 V for the an‐alog Hall unit.

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Hall unit digital Digital Hall units for MCL of Rexroth create three rectangular signals, with aphase offset of 120°. The signals from the open-collector circuit are providedat the lines according to 7-2 The voltage supply is 3 ... 24V. A minimum cur‐rent consumption of 40 mA to the Hall unit must be ensured.

Fig. 7-2: Signal course of digital Hall unit

The signal amplitude of the digital Hall unit depends on the supplyvoltage of the open-collector circuit. Bosch Rexroth controllersuse a supply voltage of 5 V.




7.1.3 Hall unit assembly/Disassembly

The Hall unit is a component that may by damaged by ESD. Be‐fore connecting the Hall unit, take appropriate measures for ESDprotection ( ESD = electrostatic discharge).

If a Hall unit on the primary part must be add on or exchanged, remove adummy or the Hall unit to be exchanged in the installation space of the sen‐sor first. To press out the dummy or the Hall unit slightly, we provide a smallauxilliary device in the accessory delivery. The existing fastening screws canbe used to assemble the new Hall unit. Do not exceed the permitted tighten‐ing torque (see Fig7-1. A too high tightening torque can damage the fasten‐ing thread of the Hall unit and can therewith make them useless.

Fig. 7-3: Hall unit assembly / disassembly1. Untighten both fastening screws. Store them to fasten a new Hall unit.

When the fastening screws are lost, only use screws of the same design(see Fig. 7-1)!

2. Press the dummy or the Hall unit by means of an auxiliary device out ofthe installation space and remove it.

3. Assemble the new Hall unitHall unit assembly - screw tightening torque

Hall unit on Screw size Strength class Tightening torque

MCP020M2.5x16

(DIN EN ISO 7045 - Torx)

8.8 0.8 NmMCP030

M2.5x5(DIN EN ISO 7045 - Torx)

MCP040M2.5x5


MCP070M2.5x8


Tab. 7-1: Tightening torque Hall unit

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7.1.4 Ordering code separate Hall unit

Primary part MCP ...Hall unit order designation

Analog Digital

015 No Hall unit available

020SUP-E01-A15-MCP020

(R911335794)SUP-E01-D15-MCP020

(R911335797)

030 ... 070SUP-E01-A30-

MCP030/040/070(R911335796)

SUP-E01-D30-MCP030/040/070

(R911335798)

Tab. 7-2: Hall unit order designation

7.2 Hall unit adapter box SHL03.1 for digital Hall unit7.2.1 General mode of functioning

If Rexroth linear motors of MCL020 ... 070 series are operated at IndraDriveCs, the Hall unit SHL03.1 adapter box enables simultaneous use of a digitalHall unit with an incremental length measuring system. By means of theSHL03.1 adapter box, the signals of these two components are connectedand forwarded to the dedicated interface at the IndraDrive Cs.

A possible circuitry with Rexroth cables is described underchapter8.3.4 "Connect digital Hall unit" on page 93

7.2.2 Ordering code

SHL03.1 adapter box

Short name SHL03.1-NNN-S-NNN

Material number R911335257

Tab. 7-3: SHL03.1 adapter box order designation




8 Connection technique8.1 Notes

Motor destruction by direct connection to the50/60 Hz mains power supply (three phase orsingle phase net)!

NOTICE

MCL motors can only be operated with suitable drive controllers with variableoutput voltage and frequency (converter mode) as specified by Rexroth.

Rexroth offers a wide range of ready-made cables for connecting MCL mo‐tors. These cables are optimally adapted to the products and a great varietyof requirements.

Note that self assembled cables or cable systems of other manu‐factures possibly do not meet these requirements. Rexroth shallnot be held responsible for resulting malfunction states or dam‐age.

8.2 Power connection8.2.1 Connection cable on primary part

Primary parts of MCL motors are fitted with a flexible and totally shielded con‐nection cable. This 1100 mm long connection cable is connected with the pri‐mary part.

① Primary part MCP② Connection cable power③ Connection cable Hall unit (optional for MCP020 ... 070;

seeFig.8-8)④ Wires with wire end ferrules (wire designation acc. to DIN EN

60445)Fig. 8-1: Design of connection cable (power) on the primary part MCP


Connection technique


Wire designation on power connection cable

Designation MCP015 1) MCP020 ... 070 1)

U BN (YE) 1 BN (YE)

V BK (GN) 2 BK (GN)

W GY (BU) 3 GY (BU)

PE not applicable GNYE

TP(+) not applicable 7 PK

TP(-) not applicable 8 WH (GY)

Shield Shield Shield

1) Colors in brackets can be transitionally available.Tab. 8-1: Wire designation (power) on MCP primary parts

Exceeding of voltage limits!DANGER

Prepare a suitable connection with a protective switch via the primary partcarrier when using AC voltage > 50 V or DC > 120 V (DIN IEC 60364-4-41)for MCP015.

Technical data connection cable Power

Frame sizeConnection ca‐

bles1)

(Bulk cable)

Diameter[D in mm]

Cross section Power wires

[mm²]

Cross section Control wire

[mm²]Coupling Flange socket

MCP015 REL0010 4.2 ±0.1 3 x 0.14 - / - Not available Not availableMCP020

REL0011 7.8 ±0.2 4 x 0.52 x 0.14

RLS1722/CM50(R911340201)

RLS1703/C01(R911388339)MCP030

MCP040REL0012 8.3 ±0.2 4 x 0.75

RLS1722/CM07(R911373943)

RLS1703/C01(R911388339)MCP070C/D/F

MCP070M INK0650 12.2 ±0.5 4 x 1.5

4 x 0.75(only 2 wires arenecessary and

lead out from thetemperature

sensor)

RLS1712/CM01(R911381140)

RLS2303/C02(R911381141)

1) Max. permitted bending radius [R]: for fix installation 5 x D; forflexible installation 7.5 x D

Tab. 8-2: Connection cable power on MCP primary parts

Routing of the connection cable The connection cable is mulded fix with the primary part and ends with opencable ends with wire end ferrules . Basically, we recommend to lead the con‐nection cable in fix installation to a junction, provided by the customer, likee.g. flange sockets or terminal boxes. Flange socket or terminal boxes mustalso be fixed with the machine construction. From this junction, a suitable ad‐ditional power cable can be laid to supply power through the energy chains orthe machine construction.

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Avoid bending, pulling and pushing loads aswell as continuous movements of the connec‐tion cable at the point where the cable exitsfrom the primary part. Any load of this kindcan lead to irreparable damage (e.g. cablebreak) on the primary part!

NOTICE

If a fixed installation is not possible, provide the connection cable with a strainrelief (see Fig. 8-2) to protect the cable and the primary part from any dam‐age (e.g. cable break).

Dimension "x" Minimum distance 5 mm① Strain relief of the connection cable on MCP primary partD Diameter connection cable (see Fig.8-2 and Fig.8-3R Observe the permitted bending radius of the connection cable

(see Tab. 8-2)Fig. 8-2: Example for strain relief of connection cable

Ground connection If the grounding of the secondary parts cannot be ensured withmounting into the customer`s machine construction, connect it ac‐cording to DIN VDE 0100-410 with the potential of the protectiveconductor .

8.2.2 Assembly Connection cable on primary partBosch Rexroth offers ready-made power cables to connect MCP primary parton Rexroth controllers. Also refer to chapter 8.2.3 .Mount the connection cable on the flange socket (RLS1704) to connect theprimary part with the power cable. Available ready-made power cables ofRexroth can be connected on these flange sockets.

The assignment of the power cables results from the motor-con‐troller-combination and can be seen in tabletab. 10-2 "Motor-con‐trol combination with IndraDrive Cs" on page 134.




① Power connector RLS1704; wire designation (on the motorside) see fig.8-1

② Connect total shield over the cable gland with the connectorhousing.

Fig. 8-3: RLS1704 connection assignment on connection cable MCP

Observe the assembly instruction, which is delivered with themale connector.

8.2.3 Connection power Bosch Rexroth provides ready-made power cables available for motor con‐nection. The cables RKL4800, RKL4801, RKL4802, RKL4803 and INK0650are optimally adjusted to our products and their most different demands.

Please observe that ready-made cables or cable systems of othermanufacturers may not fulfill these demands completely. Rexrothshall not be held responsible for resulting malfunction states ordamage.You can find additional information ...● on the selection of power and encoder cables for Rexroth

motors in documentation "Rexroth Connection CablesIndraDrive and IndraDyn" (DOK-CONNEC-CABLE*INDRV-AU□□-□□-P),

● on "Electromagnetic Compatibility in Drive and Control Sys‐tems" (DOK-GENERL-EMV********-PR□□-□□-P).

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① Rexroth drive controller② Junction (terminal box)③ Temperature sensor and ground wire available only for frame

size MCP020 ... 070. For MCP015 connect a separate protec‐tive switch with the primary part carrier acc. to DIN EN 61140for operation on voltages above protective extra-low voltage.

Fig. 8-4: Power connection on drive controller

Connection power cable in de‐pendence from primary part at

parallel arrangement

At parallel arrangement of two primary parts, the connection (phase se‐quence) of the power wires of the connection cable on the drive controller de‐pends from the direction of the cable output. Observe the notes about con‐necting power wires inchapter on page 115.




8.2.4 Installation of power connectionInstallation method for motor sin‐

gle arrangement

① Drive controller② Energy chain③ Junction (connector or terminal boxes)④ MotorFig. 8-5: Motor single arrangement

Parallel motor connection When connecting a motor parallel on a drive controller, the following possibili‐ties exist to assembly the motor cable.● Installation with two separate power cables ● Installation with a collective power cable with bigger cross section

The description of the power cables is done in the documentation"Rexroth Connection Cables", MNR R911322948 (DE) orR911322949 (EN).

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Parallel connection, installationmethod separate power cables

① Drive controller② Energy chain③ Junctions (connector or terminal boxes)④ Motor 1⑤ Motor 2Fig. 8-6: Parallel connection, separate power cables

Parallel connection, installationmethod collective power cable If this installation method (collective power cable) is used, bigger

power wire cross section can be necessary. Observe the currentrating dependent from the rated current of the motor when select‐ing the power cable

① Drive controller② Energy chain③ Junction (terminal boxes)④ Motor 1⑤ Motor 2Fig. 8-7: Parallel connection, collective power cable




8.3 Sensors8.3.1 Connection temperature sensor

All primary parts - except frame size MCP015 - are equipped with a PTC tem‐perature sensor KTY84-130. The temperature sensor is fixed within the motorwinding and serves for winding temperature measuring. The temperaturesensor itself offers no safe protection of the winding from thermal overload.The thermal monitoring of the motor must additionally be done via a workingtemperature modell in the controller.Heed the right polarity of the connection wires when connecting theKTY84-130 . The wire designation can be found under Fig. 8-1.For additional information on the temperature sensor, please refer to chapter9.10 "Motor temperature monitoring" on page 107.

● Temperature sensor KTY84-130 is a component that mightby damaged by ESD! For this reason, the wires of the sen‐sor are protected by a protective foil at the connection cable.Before connecting the sensor, take measures regardingESD protection.( ESD = electrostatic discharge).

● The used temperature sensors are double or reinforced in‐sulated according to DIN EN 50178, so separation exists ac‐cording to DIN EN 61800-5-1.

8.3.2 Connection Hall unitMotors with Hall unit have an additional cable to connect the sensor. This ca‐ble is beside the connection cable for the power. After motor installation, thecable of the Hall unit can be shortened to the required length and be assem‐bled with a D-sub connector, 9-pole (pin), for example. Also refer to Chap.8.3.3 .

① Primary part MCP② Connection cable power (see chapter 8.2.1 "Connection cable

on primary part" on page 83)③ Connection cable Hall unit (optional for MCP020 ... 070)④ Wires with wire end ferrulesFig. 8-8: Wire designation connection cable Hall unit

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Connection cable Hall unit

Motor frame size Diameter [D]Cross section Control wire

[mm²]Allowed bending radius [R]*

MCP020 ... 070 4.2 ±0.1 6 x 0.14- for fix installation 5 x D

- for flexible installation 7.5 x D*) See notes regarding bending radius under Fig.8-2

Tab. 8-3: Connection cable Hall unit on primary parts MCP020 ... 070

Avoid bending, pulling and pushing loads aswell as continuous movements of the connec‐tion cable at the point where the cable exitsfrom the primary part. Any load of this kind,can lead to irreparable damage (e.g. cablebreak) on the primary part!

NOTICE

The connection cable of the Hall unit can be connected with the power cablevia cable ties, if the power cable is provided with a strain relief. If a fixed in‐stallation is not possible, equip the connection cable of the Hall unit withstrain relief (for example, see Fig. 8-2) to protect the cable and the primarypart from any damage (e.g. cable break).

The Hall unit is a component that may by damaged by ESD. Forthis reason, the wire ends on the connection cable are protectedwith a protective foil. Before connecting the Hall unit, take appro‐priate measures for ESD protection ( ESD = electrostatic dis‐charge).

For more information about the Hall unit, please refer to chapter 7.1 "Hallunit" on page 77.




8.3.3 Assembly Hall unit connection cableBefore the Hall unit can be connected to the SHL03.1 adapter box, the con‐nection cable of the Hall unit must be assembled with a 9-pole D-sub connec‐tor (RGS0005). The assignment

Connection cable Hall unit

analog digital

1 12 V (BN) 12 V (BN)

2 A+ (GY) S1 (YE)

3 A- (YE) /

4 0V (WH) S2 (GN)

5 B+ (PK) 0V (WH)

6 B- (GN) /

7 / /

8 / S3 (PK)

9 / /

Connector housing Outer shield Outer shield

Tab. 8-4: Connection assignment RGS0005 for Hall unit connection

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8.3.4 Connect digital Hall unitTo connect a digital Hall unit in connection with an incremental length meas‐uring system on a conroller of the IndraDrive Cs family, use the SHL03.1adapter box.The SHL03.1 brings both incoming signal cables of Hall unit and lengthmeasuring system together and redirects their signals via a single connectioncable to the drive controller for encoder evaluation.

① Flange socket RGS0006 (D-sub connector 15-pole (pins))② Flange socket RGS0005 (D-sub connector 9-pole (pins))① Flange socket RLS1704RKL480x Motor power cables (max. cable length 75 m)RKG0049 Adapter box ↔ encoder evaluation on drive controller (max. ca‐

ble length 75 m)RKG0050 Digital Hall unit ↔ adapter box (max. cable length 30 m)RKG0051 Length measuring system ↔ adapter box (max. cable lengths

75 m)Fig. 8-9: Connection overview MCP with digital Hall unit

● The total distance between drive controller and the head ofthe length measuring system and/or the Hall unit must notexceed a length of 75 m!

● Observe further notes about the SHL03.1 adapter box in thedocumentaion DOK-INDRV*-HCS01******-PRxx-xx-P, MNRR911322210 and under chapter 7.2 "Hall unit adapter boxSHL03.1 for digital Hall unit" on page 81.




8.3.5 Connect analog Hall unitTo connect an absolute measuring system and an analog Hall unit, a shelfwith 2 encoder interfaces in the IndraDrive Cs controller is necessary.

① Flange socket RGS0006 (D-sub connector 15-pole (pins))② Flange socket RGS0005 (D-sub connector 9-pole (pins))③ Flange socket RLS1704RKL480x Motor power cables (max. cable length 75 m)RKG0049 Length measuring system ↔ Encoder evaluation at drive con‐

troller (max. cable length 75 m)RKG0052 Analog Hall unit ↔ encoder evaluation on drive controller (max.

cable length 75 m)Fig. 8-10: Connection overview MCP with analog Hall unit

8.4 Length measuring system The length measuring system is not in the scope of delivery of themotor and must be prepared and assembled by the maschinemanufacturer (see chapter 9.14 "Length measuring system" onpage 120).

Setting the encoder polarity depends on the direction of rotation of the pri‐mary part and must be parameterized at start-up of the controller. Also ob‐serve the manufacturer's instruction of the length measuring system.To connect an incremental length measuring system on a Rexroth controlleror on the adapter box SHL03.1, Bosch Rexroth provides two connection ca‐bles.● RKG0049 for connection of the length measuring system directly on the

controller● RKG0051 to connect the length measuring system on the SHL03.1To use this connection cable, fit the connection cable on the incrementallength measuring system with a compatible flange socket (RGS0006).

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Signal Function

1 GND_shld Connection signal shields (inner shields)

2 A+ Track A positive

3 A - Track A negative

4 GND_Encoder Reference potential voltage supplies

5 B+ Track B positive

6 B - Track B negative

7 n.c. /

8 n.c. /

9 R+ Reference track positive

10 R- Reference track negative

11 VCC_Encoder (12V) Encoder supply 12 V

12 VCC_Encoder (5 V) Envoder supply 5 V

13 n.c. /

14 n.c. /

15 Sense-Feedback of reference potential

(Sense line)

Connectorhousing / Outer shield

Tab. 8-5: Connection assignment to be done on RGS0006 to connect thelength measuring system on the customer-side




9 Application and construction instructions9.1 Mode of functioning

The force generation for an ironless synchronous-linear motor, is the sameas the torque generation at rotary synchronous motors. The ironless primarypart (active part) has a winding; the secondary part (passive part) has perma‐nent magnets.Both, the primary part and the secondary part can be moved.Realization of any traverse path lengthcan be done by stringing together sev‐eral secondary parts.

Axis construction The MCL motor is a kit motor. The components primary and secondarypart(s) are delivered separately and completed by the user via linear guideand the linear measuring system. They are mounted into the machine or sys‐tem.The construction of an axis fitted with a linear motor normally consists of● Primary part with Hall unit● one or more secondary parts with permanent magnets● Length measuring system● Linear guide● Energy flow● Slide or machine constructionFor force multiplication can be two or more primary parts mechanically cou‐pled, arranged in-line. For further information see chapter 9.13.2 "Severalmotors per axis" on page 113.

Only the primary and the secondary part(s) belong to the scope ofdelivery of the motor. Linear guide and length scale as well as fur‐ther additional components have to be made available by theuser.

9.2 Motor design9.2.1 Design primary part

The primary part consists of an u-shaped aluminum primary part carrierwhich bears the coil body and is molded with plastic resin. This mold servesfor mechanical property of the MCP. It is no protection against humidity, for‐eign bodies or touch of electrically active parts. Due to the mold process,sometimes small blowholes can occur on the surface of the mold. They arenot relevant for the function and mechanical property of the motor. The motorcooling happens due to the thermal couplingof the primary part on the ma‐chine and via the natural convection.


Application and construction instructions


① Primary part carrier out of aluminum② Form of molded motor winding in design I-form (MCP020 ...

070)③ Form of molded motor winding in design T-form (MCP015)Fig. 9-1: Design MCP primary part

9.2.2 Design secondary part The MCS consists of an u-shaped screwed steel base plate with adheredpermanent magnets. All fastening holes are in the fastening rail along thesecondary part.To ensure a high corrosion protection , the iron parts of the secondary partare nickel-plated and the permanent magnets are coated with epoxy.

① Permanent magnets② Screwed secondary part bodyFig. 9-2: Secondary part MCS040

Available lengths secondary parts Secondary parts are available in different lengths. Please also refer to the da‐ta underType code.

Required length of the secondaryparts

The required length L of the secondary part can be defined as follows:

Fig. 9-3: Defining the required length of the secondary part

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9.2.3 Frame size and frame lengthFor adjusting on different feed force requirements, Bosch Rexroth offers MCLmotors in a modular system in different sizes and lengths.

Frame sizes The designation of frame size is derived from the active height lFe and powerof MCL.

Fig. 9-4: lFe = Active magnet heigthAccording to this system, the MCL modular construction system contains thefollowing motor frame sizes:● MCP015 / MCS015● MCP020 / MCS020● MCP030 / MCS030● MCP040 / MCS040● MCP070 / MCS070

Frame lengths Primary and secondary parts of one size are graduated additionally to differ‐ent frame sizes. The length designation of the primary part in the type code isdone via code letters, like A, B, C. The length designation of the secondarypart in the type code is given directly by the length in mm.

For detailled information about the available frame sizes andlengths please refer to the Type code of the motor.




9.3 Installation altitude and ambient conditionsThe motor performance data specified are applicable for● Ambient temperature 0 ... +40 °C● Setup elevation of up to 1,000 m above sea level.Different conditions lead to a departing of the data according to the followingdiagrams. Do occur deviating ambient temperatures and higher installationaltitude at the same time, both utilization factors must be multiplied.

① Usability to capacity, depending on the surrounding air temper‐ature

② Usability to capacity, depending on the installation altitudefT Temperature utilization factortA Ambient temperature in degrees CelsiusfH Height utilization factorh Installation altitude in metersFig. 9-5: Derating of ambient temperature, installation altitude (in operation)Calculation of performance data in case the limits specified are exceeded:Ambient temperature > 40 °CFN_red = FN × fT Installation altitude > 1,000 mFN_red = FN × fH Ambient temperature > 40 °C and setup elevation > 1,000 mFN_red = FN × fT × fH

The details for the utilization depending from the installation alti‐tude and environmental temperature do not only apply to the mo‐tor , but on the whole drive system, consisting of motor, drive con‐troller and mains supply. Ensure that the reduced data are not ex‐ceeded by your application.

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9.4 Environmental conditions during operationEnvironmental conditions are defined according to DIN EN 60721-3-3 in dif‐ferent classes. They are based on long-term experiences and take all influ‐encing variables into account, e.g., air temperature and air humidity.Overview of allowed classes of ambient conditions according to DIN EN60721-3-3 during operation

Classification type Allowed class

Classification of climatic environmental conditions 3K22

Classification of biological environmental conditions 3B1

Classification of mechanically active materials 3S6

Classification of mechanical environmental conditions 3M12

Tab. 9-1: Allowed classes of environmental conditions during operationBased on DIN EN 60721-3-3, some limit values are partially defined in thefollowing, which our products are allowed to be exposed to during operation.Observe the detailed description of the classifications to take all of the factorswhich are specified in the particular class into account.Allowed operation conditions

Environmental factor Unit Value

Air temperature °C 0 ... +40

Air humidity (relative) % 5 … 95

Air humidity (absolute) g/m³ 1 ... 29

Tab. 9-2: Operating conditionsUnless otherwise specified, the values given are the values of the particularclass. However, Bosch Rexroth reserves the right to adjust these values atany time based on future experiences or changed environmental factors.




9.5 Type of protectionThe design of MCL motors is according to protection mode according to DINEN 60034-5.

Motor component Type of protection

Primary part(Front face MCP020 ... 070)

IP00(IP20)

Secondary part IP00

Hall unit IP00

Tab. 9-3: Protection modes on MCL motors

● The mold of primary parts serves for mechanical property.This is no protection against humidity. Due to the coatingthickness of the mold for MCP020 ... 070, only a small pro‐tection against foreign bodies or touch of dangerous electricvoltage is ensured on the front sides (cable output and oppo‐site side). Therefrom, the protection mode IP20 is derived onthe front.

● Observe the notes under chapter 9.12.4 "Protection of themotor installation space" on page 112 regarding protectionmodes.

Any failure to observe the degree of protec‐tion of the motor may damage or destroy themotor components or result in personal in‐jury!

CAUTION

The motors or components may only be used in environments where the de‐gree of protection specified is adequate.

9.6 Acceptances and approvals9.6.1 CE

Certificate of conformity certifying the structure of and the compliance withthe valid EN standards and EC guidelines are available for all motors. If re‐quired, the declarations of conformity can be requested from the responsiblesales office. The CE mark is attached to the motor type label of the motors.

9.6.2 EAC

EAC stands for Eurasian Conformity.Motors of MCL series fulfill the specified technical requirements of the EACmember states in the tariff union. The member states are Russia, Belarusand Kazakhstan.

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9.6.3 RoHSWe confirm in our manufacturer´s declaration TC 30806-1 that our productsconfirm with the RoHS directive 2011/65/EG "Restriction of the use of certainhazardous substances in electrical and electronic equipment".

9.6.4 China RoHS 2

25Motors of the MCL series are according to the specifications of standard SJ/T11364 and they have an EFUP (Environmentally friendly use period) of 25years. A corresponding labeling is in preparation). For more information, referto https://www.boschrexroth.com.cn/zh/cn/home_2/china_rohs2 www.bos‐chrexroth.com.cn/zh/cn/home_2/china_rohs2 in section "Kit motors".

9.7 Magnetic fieldsDuring operation of electric motors, electromagnetic fields are generated atlive components and connection lines of these motors. The secondary partsequipped with permanent magnets of synchronous linear motors and rotorsof synchronous kit motors are magnetically not shielded and permanentlygenerate a static magnetic field (DC field) even if not activated. This is indica‐ted by a warning label attached to each package with open permanent mag‐net components.if all regulations and safety measures are complied with, synchronous kit mo‐tors with open permanent magnet components do not cause any inadmissiblehazards. As of a distance of approx. 100 mm to the surface of open perma‐nent magnet parts, there is practically no effective magnetic attraction of fer‐romagnetic parts. However, for people with implants, a minimum safety dis‐tance of 1 meter (1000 mm) is recommended.Depending on the operating location, transport ways and storage of the ma‐chine and its components, local regulations and laws apply and have to becomplied with during construction, transport and operation of the machine.

Electromagnetic / magnetic fields! Healthhazard for persons with heart pacemakers,metal implants or hearing aids! Material dam‐age.

WARNING

Hazards due to magnetic and electromagnetic fields at livecomponents or permanent magnets of electric motors.

Persons with active implantable medical devices (AIMD) orpassive metallic implants must keep clear from these motorcomponents.The above-specified persons are prohibited from accessingareas where such drive components are installed and operat‐ed or access is subject to prior medical consultation.Keep magnetic data carriers, credit cards, check cards andidentity cards and all ferromagnetic metal parts away frommagnetic fields. Do not wear jewelry, particularly made of fer‐romagnetic material, during work at magnetic components.




Safety measures for operatingpersonnel

In the European Community (EU), directive 2004/40/EC specifies minimumrequirements for protection of the safety and health of employees from haz‐ards due to electromagnetic and magnetic fields. Regulations and guides formachine manufacturers and machine operators are included in the followingdocuments:● Standard EN 50499 (Germany: DIN EN 50 499, DIN VDE 0808-499)● Standard EN 50527 (Germany: DIN VDE 0848-3)● In Germany: Accident prevention regulations BGV/GUV-V B11This list does not claim to be exhaustive. Machine manufacturers and ma‐chine operators are required to define the regulations applicable on site andthe occupational health and safety measures to be applied for working in thearea of exposition. The decisive factors are not the electromagnetic proper‐ties of individual machine components but the effective overall exposition inelectrical, magnetic and electromagnetic fields in the actual working area.

Construction information During construction of the machine, suitable covers and safety equipment forsafe operation must be applied.● During construction of the machine, observe applicable standards and

regulations on marking of and access to exposition areas.● Prevent any access of operating personnel in the motion range of mo‐

tors during operation.● Prevent any contamination, chips and dirt in the motion range of motors.

Notes on transport For shipping by air freight of magnetic components, the limit values for mag‐netic flux density in all directions in accordance with IATA953 must be com‐plied with. All rotors of Bosch Rexroth synchronous motors comply with cate‐gory I according to the figure below. Depending on their geometry and con‐struction, the secondary parts of Bosch Rexroth linear motors comply withone of the three listed categories. Before shipping, the category of the pack‐age must be determined.

CategoryDistance to theedge of the pack‐age

Flux density Measure

I 2.1 m≤ 0.525 µT≤ 5.25 mG

Package does not require decla‐ration and marking for shipping.

II 4.6 m≤ 0.525 µT≤ 5.25 mG

Declaration and marking asmagnetic material is required.

III 4.6 m> 0.525 µT> 5.25 mG

Shipping requires prior approvalof responsible national authori‐ties in the country of dispatchand the state of the air freightcarrier.

Tab. 9-4: Limit values of magnetic flux density for air freight

9.8 Noise emissionThe noise emission of synchronous linear drives can be compared with con‐ventional inverter-operated feed drives. Empirically, it is dependent from thefollowing factors:● the employed linear guides (velocity-related travel noise),● used length measuring system,

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● mechanical construction (rotating covers, a.s.o.)● The settings of drive and controller (e.g. switching frequency)

9.9 Thermal behaviorPower loss The rated feed force of a synchronous linear motor can be achieved is mainly

determined by the power loss PV produced during the energy conversionprocess. The power loss fully dissipates in form of heat. Due to the limitedpermissible winding temperature it must not exceed a specific value.

The allowed winding temperature of the motors is 130 °C.

The total loss of synchronous linear motors are significantly defined by theshort-circuit loss of the primary part.

PV Total loss in WPVI Short-circuit loss in WI Current in motor cable in AR12 Electrical resistance of the motor at 20 °C in Ohm (see Chapter

4 ”Technical data”)fT Factor temperature-related resistance raiseΔT Temperature increase in Kα20 Temperature coefficient of cupper in 1/KFig. 9-6: Power loss of synchronous linear motors

When you determine the power loss according to Fig. 9-6 youmust take the temperature-related rise of the electrical resistanceinto account. At a temperature rise of 100 K (from 20 °C up to120 °C), for example, the electrical resistance goes up by the fac‐tor fT = 1.39.

Thermal time constant The temperature variation vs. the time is determined by the produced powerloss and the heat-dissipation and –storage capability of the motor. The heat-dissipation and –storage capability of an electrical machine is (combined inone variable) specified as the thermal time constant.The following figure (Fig. 9-7) shows a typical heating and cooling process ofan electrical machine. The thermal time constant is the period within which63% of the final over temperature is reached.Together with the duty cycle, the correlation to Fig. 9-8 and Fig. 9-10 areused to define the operating modes, e.g. acc. to DIN EN 60034-1.




Fig. 9-7: Heating up and cooling down of an electrical machineHeating up

ϑe Final excess temperature in Kϑa Initial excess temperature in Kt Time in mintth Thermal time constant in min (see motor data sheet)Fig. 9-8: Heating (excessive temperature) of an electric machine

Final over temperature Since the final over temperature is proportional to the power loss, the expec‐ted final over temperature ϑe can be estimated according to:

Pce Continuous power loss or average power loss over cycle dura‐tion in W (see chapter 11.4 "Determining the drive power" onpage 150)

PvN Nominal power loss of the motor in Wϑemax Maximum final over temperature of the motor in KFeff Effective force in N (from application)Fdn Continuous nominal force of motor in N (see motor data sheet)Fig. 9-9: Expected final over temperature of the motor

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Cooling down

ϑe Final excess temperature or shutdown temperature in Kt Time in mintth Thermal time constant in min (see motor data sheet)Fig. 9-10: Cooling down of an electrical machine

9.10 Motor temperature monitoringThe motor temperature is monitored by two systems that are operated inde‐pendently of each other● Temperature sensor (motor)● Temperature model (controller)and ensures thus the best protection of motors against irreversible damageby thermal overload.Primary parts of frame sizes MCP020 ... 070 are standardly fitted with an in‐tegrated temperature sensor (KTY84-130) for measuring the winding temper‐ature. An all-phase monitoring is impossible with only one KTY. Thus, it ispossible that a phase in standstill operation with continuous currents are nearthe rated current, which is monitored by a KTY, is thermally overloaded, de‐spite the KTY only displays measuring values < 110°C. The exclusive use ofthe KTY for temperature monitoring means no sufficient motor protection forthe primary parts.

A possible form of an additional motor protection is, to limit themotor current to 87% of the rated current at low velocity (< 1 m/min) or at movement via a short traverse path (< 2 · tP).

The Rexroth IndraDrive control devices monitor the functionality of the tem‐perature sensors. For more information, please refer to the functional de‐scription for IndraDrive controllers.

Standstill operation For safe operation of MCL in standstill observe the information in chapter9.23 .

Temperature sensor KTY84-130 KTY84-130 Value

Resistance at 25 °C min. 577 ... max. 629 Ohm

Resistance at 100 °C min. 970 ... max. 1000 Ohm

Continuous current at 100 °C 2 mA

Tab. 9-5: Standard values on temperature sensors KTY84-130The response temperatures of the sensor are⇒110 °C pre-warning temperature⇒130 °C shut-off temperature




Fig. 9-11: Characteristic temperature sensor KTY84-130

KTY84-130 is an ESD sensitive device! For this reason, the wiresof the sensor are protected by a protective foil at the connectioncable. Before connecting the sensor, take appropriate measuresfor ESD protection ( ESD = electrostatic discharge).To connect temperature sensors heed the details under chapter8.3.1 "Connection temperature sensor" on page 90.

9.11 Feed force at reduced covering between primary and secon‐dary part

When moving in the end position range of an axis, it can be necessary thatthe primary part moves beyond the end of the secondary part. This results ina partial coverage between primary and secondary part.If primary and secondary part are only partially covered, a reduced feed forceand attractive force results.

Inserted force reduction Outside the beginning and end areas (sR1 or sR2), the reduction of the force islinear with the reduced overlap area.The following diagram illustrates the correlation between the coverage be‐tween primary and secondary part and the resulting force reduction.

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Fig. 9-12: Force reduction with partial coverage of primary and secondary part

Motor version SR1 [mm] SR2 [mm]

without Hall unit Installation position 1

MCL015 0.5 0.5

MCL020 ... 70 6.5 0.5

Installation position 2

MCL015 0.5 0.5

MCL020 ... 70 0.5 6.5

with Hall unit

If a Hall unit is used for commutation, the primary part on the cable output side mustbe completely within the secondary part. During operation, which is normally withoutanalysis of the Hall unit, the primary part can be operated as described under "with‐out Hall unit".

Tab. 9-6: Partial coverage vs. installation positionThe partial coverage of primary and secondary parts must not be used incontinuous operation since there is an increased current consumption of themotor due to control strategies. Instabilities in the control loop can be expec‐ted from a certain reduction of the degree of coverage onwards.




9.12 Requirements on the machine design9.12.1 General

Derived from design and properties of linear direct drives, the machine con‐struction must meet various requirements. For example, minimizing of mov‐ing masses with simultaneous high rigidity should be realized.

9.12.2 Mass reductionTo ensure a high acceleration capability, the mass of the moved machine ele‐ments must be reduced to a minimum. This can be done by using materialsof a low specific weight (e.g. aluminum or compound materials) and by de‐sign measures (e.g. half-timbered construction).If there are no requirements for the highest acceleration, even relative bigmass can be moved. A very rigid coupling of the motor to the weight is a pre‐condiiton.

9.12.3 Mechanical rigidityIn conjunction with the mass and the resulting resonant frequencies, the ri‐gidity of the individual mechanical components within a machine chiefly de‐termines the quality a machine can reach. The rigidity of a motion axis is de‐termined by the overall mechanical structure. The goal of the constructionmust be to obtain an axis structure that is as compact as possible.

Natural frequency The increased loop bandwidth of linear drives required higher mechanicalnatural frequencies of the machine structure in order to avoid the excitation ofvibrations.To ensure a sufficient control quality, the lowest natural frequency that occursinside the axis should not be less than approximately 200 Hz. The natural fre‐quencies of axes with masses, that are not constantly moving (e.g. due towork pieces that must be machined differently), change, so that the natural

frequency is reduced as the mass increases. Mechanically coupled axes With the stiffness of kinematically coupled axes, it should be taken into ac‐

count that the flexibility of the axes - both the mechanical and the controlcomponents - add up.If several axes must be coupled cinematically in order to produce path mo‐tions (e.g. cross-table or gantry structure), the mutual effects of the individualaxes on each other should be minimized. Thus, cinematic chains should beavoided in machines with several axes. Axis configurations with long projec‐tions that change during operation are particularly critical.

Reactive forces Initiated by acceleration, deceleration or process forces of the moved axis,reactive forces can deform the stationary machine base or cause the fixedmachine base body to vibrate.

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Fig. 9-13: Deformation of the machine base body caused by the reactive forceduring the acceleration process

Δs Deformation or displacement of the machine base body in µmm Mass in kga Acceleration in m/s²c Rigidity of the machine base body in N/µmFig. 9-14: Calculation example of the machine base body deformation

Integrating the linear scale The rigidity of the length measuring system integration is particularly impor‐tant. For explanations refer to chapter 9.14 "Length measuring system" onpage 120.




9.12.4 Protection of the motor installation spaceDue to protection mode IP00 of the motor components, the protection of themotor installation space need especial observance. To avoid that dirt comesinto the air gap between primary and secondary part (e.g. due to any kind ofresidues, dust, etc.) during motor operation, the motor installation space mustbe designed according to the environmental conditions. The motor installationspace must be designed in such a way, that the protection class IP65 accord‐ing to DIN EN 60034-5 equivalent environmental conditions are ensured (seechapter 9.5 "Type of protection" on page 102).Heed appropriate protection measures when designing the machine con‐struction. If dirt gets between the motor components due to insufficient pro‐tection measures, during operation this can lead to...● an increased heat introduction due to friction between the motor compo‐

nents. Thereby, temperatures can arise, which can cause a motor dam‐age.

● Due to the high mechanical force effectgrinding traces and /or scratch-formation on the motor components can result in the destroying of cast‐ing compounds on the primary part, to motor breakdown,, among oth‐ers.

Please note that dirt can also enter indirectly into via compressed air or dueto other machine parts (e.g. grease of the guides). This must be prevented.Make sure by regularly maintenance of the safety measures that their func‐tion is still kept and the motor components could not be damaged.

9.13 Arrangement of motor components9.13.1 Single arrangement

The single arrangement of the primary part is the most common arrange‐ment. One or more primary parts can be controlled independently of eachother. In such an arrangement, the length measuring system can also beequipped with two or more scanning heads.

Fig. 9-15: Single axis arrangement of primary parts

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① Control unit② Controller③ Length measuring systemFig. 9-16: Controlling a linear motor with single arrangement of the motor com‐

ponents

9.13.2 Several motors per axisThe arrangement of several motors per axis provides the following benefits:● Multiplied feed forces● Optimized utilization of available installation space

Fig. 9-17: Examples for arrangementDepending on the application, the motors can be controlled in two differentways:● Two or more motors at one drive controller and one linear scale (parallel

connection)● Two motors at two drive controllers and two linear scales (Gantry ar‐

rangement)




Parallel connection: Several primary parts in parallelThe arrangement of two or more primary parts on one drive controller in con‐junction with a linear scale is known as parallel arrangement.

① Control unit② Controller③ Length measuring systemFig. 9-18: Parallel connection of two primary parts on one drive controller in

conjunction with a length measuring systemTo ensure successful operation, the following conditions must be fulfilled:● Use identical primary parts MCP and same line length MCS● Stiff motor coupling within the axis● Position offset between the primary parts <1 mm in feed direction● Position offset between the secondary parts <1 mm in feed direction● If possible, load stationary and arranged symmetrically with respect to

the motorsThe determination of the distance that must be adhered depends on the di‐rection of the cable outlet and the permissible bending radius of the powercable.

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Parallel connection: Gantry arrangement (primary parts in a row)For parallel connection, primary parts in feed direction can also be arrangedin a row, mechanically coupled.To ensure successful operation, the primary parts must be arranged in a spe‐cific distance to each other and must fulfill the following conditions. The deter‐mination of the grid dimension that must be adhered, depends on the direc‐tion of the cable outlet and the permissible bending radius of the power ca‐ble.

Cable outlet in the same direction If the primary parts are arranged behind each other and with cable outlets in‐to the same directions to Fig. 9-19 a distance xP must be kept.

Fig. 9-19: Arrangement of the primary parts behind each other and cable outletin the same direction

xP Distance between the front faces of the primary parts in mmn Freely selectable integer factor ≥ 0τp Pole width see Chapter Technical data)xPmin smallest allowed distance between the primary parts (see Tab.

9-7)R Allowed bending radius of the connection cable (see Tab. 8-2)Fig. 9-20: Determining the distance xP between the primary parts with cable

outlet in the same directionThe grid dimension ΔxP acc. to Fig. 9-19 must be a integer multiple of thedouble pole width. Always use the same reference point for both primaryparts (e.g. the same fastening hole or the same primary part front side).

Δxp Required grid spacing between the primary parts in mmm Freely selectable integer factor ≥ 0τp Pole width see Chapter Technical data)Fig. 9-21: Determining the grid dimension between the primary parts with cable

outlet in the same directionThe distance xP between the primary parts according to Fig. 9-19 my not de‐ceed the minimum distance xPmin:




Primary part Distance xPminPhase sequence

Primary part 1*) Primary part 2

MCP015 4.5 mm

U-V-W

V-W-U

MCP02053 mm63 mm73 mm

U-V-WV-W-UW-U-V

MCP030 ...070C/D/F

53 mm73 mm93 mm

U-V-WV-W-UW-U-V

MCP070M73 mm93 mm113 mm

V-W-UW-U-VU-V-W

*) Reference motor to determine the encoder polarity and com‐mutation adjustment is always primary part 1

Tab. 9-7: Distance and phase sequence at arranged primary parts behindeach other and cable outlet in the same direction

Cable outlet in opposite direction(variant 1: back to back)

If the primary parts are arranged behind each other and with cable outlets inopposite directions to Fig. 9-22, a defined distance xP must be kept betweenthe primary parts.

Fig. 9-22: Variant 1: Arrangement of primary parts behind each other with ca‐ble outlets in opposite directions


9-8)Fig. 9-23: Determining the distance between primary parts with cable outlets in

opposite directions

When determining the correct primary part distance according toFig.9-22, only the distance between the primary part end faces(xpmin) as reference point can be used.

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MCP015 1.75 mm U-V-W U-W-V

MCP020

3 mm

U-V-W

U-W-V

13 mm W-V-U

23 mm V-U-W

MCP030 ... 070

8 mm

U-V-W

U-W-V

28 mm W-V-U

48 mm V-U-W


Tab. 9-8: Distance and phase sequence at arranged primary parts behindeach other with cable outlets in opposite directions (option 1)

Cable outlet in opposite direction(variant 2: cables to each other)

If the primary parts are arranged behind each other and with cable outlets inopposite directions to Fig. 9-24, a defined distance xP must be kept betweenthe primary parts.

Fig. 9-24: Variant 2: Arrangement of primary parts behind each other with ca‐ble outlets in opposite directions


9-9)R Allowed bending radius of the connection cable (see Tab. 8-2)Fig. 9-25: Determining the distance xP between the primary parts with cable

outlet in the same direction

When determining the correct primary part distance according toFig.9-24, only the distance between the primary part end faces(xpmin) as reference point can be used.






MCP015 1.75 mm U-V-W W-V-U

MCP020

53 mm

U-V-W

W-V-U

63 mm V-U-W

73 mm U-W-V

MCP030 ...MCP070C/D/F

58 mm

U-V-W

W-V-U

78 mm V-U-W

98 mm U-W-V

MCP070M

78 mm

U-V-W

V-U-W

98 mm U-W-V

118 mm W-V-U


Tab. 9-9: Minimum distance and phase sequence at arranged primary partsbehind each other with cable outlets in opposite directions (option 2)

Gantry arrangementIf different load conditions occur during operation, both locally and temporally,and a sufficient rigidity between the motors cannot be ensured, the operationshould be planned with two linear scales and drive controllers (Gantry ar‐rangement). This is frequently the case with axis in a Gantry structure, for ex‐ample.

Within a Gantry arrangement, even parallel connected motors canbe used.

Double comb arrangement (Gantry)Within a Gantry arrangement, the primary parts in feed direction can be me‐chanically coupled and arranged in the form of a double comb arrangement.

① Control unit② Controller (2 pcs.)③ Length measuring system (2 pcs.)Fig. 9-26: Gantry arrangement (double comb)With Gantry arrangements it must be remembered that the motors may bestressed asymmetrically, although the position offset is minimized. As a con‐sequence, this permanently existing base load may lead to a generally higherstress than a single arrangement. This must be taken into account when thedrive is selected.

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The asymmetric capacity can be reduced to a minimum by exact‐ly aligning the length measuring system and the primary and sec‐ondary parts to each other, and by an internal axis error correc‐tion.

Arrangement of primary parts in a row (Gantry)Primary parts in feed direction can also be arranged in a row, mechanicallycoupled.

① Control unit② Controller (2 pcs.)③ Length measuring system (1 scale, 2 scanning heads)Fig. 9-27: Gantry arrangement (primary parts in a row)

9.13.3 Arrangement of secondary partsDuring assembly, you must not heed the arrangement of the secondary parts.Due to construction of MCS, a "polarity reversal" - arrangement of severalsecondary parts within a path is prevented. The order of magnetization is un‐changed by a 180° - rotation of secondary parts.Please observe the notes in chapter 13.4 "Air-gap, parallelism and symmetryof the motor components" on page 160 and chapter 13.5 "Fastening secon‐dary part" on page 161 about alignment and fastening of secondary parts.

9.13.4 Vertical axis

Uncontrolled movements! Risk of injuries!CAUTION

Motors in vertical axes are not self-locking when de-energize. Prevent a sink‐ing of the axis with appropriate holding devices.

● On vertical axis, the use of an absolute measuring system isrecommended.

● Incremental measuring systems can only be used, if a Hallunit is additionally used beside the holding device.

Weight compensation An additionally used weight compensation ensures that the motor is not ex‐posed to an unnecessary thermal stress that is caused by the holding forcesand the acceleration capability of the axis is independent of the motion direc‐tion. The weight compensation can be pneumatic or hydraulic. Weight com‐pensation with a counterweight is not suitable since the counterweight mustalso be accelerated.




9.14 Length measuring system9.14.1 General

A linear measuring system is required for measuring the position and the ve‐locity. Particularly high requirements are placed upon the linear scale and itsmechanical connection. The length measuring system is used for high-resolu‐tion position recognition and the determination of the actual velocity.

The necessary length measuring system is not in the scope of de‐livery of Bosch Rexroth and has to be provided and mounted fromthe machine manufacturer themselves(tab. 9-10 "Manufacturersof length measuring systems" on page 121).

Fig. 9-28: Classification of linear scalesParticularities of synchronous line‐

ar motorsIt is necessary at synchronous linear motors to receive the position of the pri‐mary part relating on the secondary part by return after start or after a mal‐function (pole position recognition). Using an absolute linear scale is the opti‐mum solution here.

9.14.2 Selection criteria for length measuring systemGeneral

Depending on the operating conditions, open or encapsulated linear scaleswith different measuring principles and signal periods can be used. The se‐lection of a suitable linear scale mainly depends on:● The maximum feed rate (model, signal period)● The maximum travel range (measuring length, model)● If applicable, utilization of coolant lubricants (model)● Incidental dirt, chips, etc. (frame size)● the accuracy requirements (signal period)

Manufacturers of length measuring systemsThe following selection is exemplary and does not claim to be complete. Youcan also use products from other manufacturers, according to the encoder in‐terface of the used controller.

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Bosch Rexroth AGLinear and assembly techni‐

que

Maria-Theresien-Straße 2397816 Lohr am Main, Germany

[email protected]://www.boschrexroth.com/business_units/brl/de/(Integrated measuring system for profiled rail guide)

AMO Automatisierung Mes‐stechnik Optik GmbH

NÖFING 4A-4963 ST. PETER AM HART

[email protected]://www.amo-gmbh.com

DR. JOHANNES HEIDEN‐HAIN GmbH

Postfach 126083292 Traunreut, Germany

[email protected]://www.heidenhain.de/

NUMERIK JENA GmbH

Ilmstraße 407743 Jena, Deutschland

[email protected]://www.numerikjena.de/

Renishaw GmbHKarl-Benz Straße 12

72124 Pliezhausen, Germanyhttp://www.renishaw.de/

SICK AGErwin-Sick-Straße 1

79183 Waldkirch, Germanyhttp://www.sick.com/

SIKO GmbH

Weihermattenweg 279256 Buchenbach, Germany

[email protected]://www.siko.de/

Tab. 9-10: Manufacturers of length measuring systems

● To ensure maximum interference immunity, Rexroth recom‐mends the voltage interface with 1 VSS.

● Please refer to the documents from the corresponding man‐ufacturer for detailed and updated information.

Measuring system cablesReady-made cables of Rexroth are in preparation for the electrical connec‐tion between the output of the linear scale and the input of the scale inter‐face. To ensure maximum transmission and scale interference safety, youshould preferably use these ready-made cables.

9.15 Linear guiding systemsLinear guiding systems for linear motors are, depending on the motor ar‐rangement, necessary due to feed and process forces as well as the speedsachievable today. The used linear guiding system must be able to adjustprocess and acceleration force.Depending on the application, the following linear guides are employed:● Ball or roll rail guides




● Slide ways● Hydrostatic guides● Aerostatic guidesThe following requirements should be taken into account when a suitable lin‐ear guide system is selected:● High accuracy and no backlash● Low friction and no stick-slip effect● High rigidity● Steady run, even at high velocities● Easy mounting and adjustment

Manufacturer Linear guiding systems are not in the scope of delivery of the mo‐tor and must be ordered separately. The selection of a suitablelinear guiding system is in the sole responsibility of the machinemanufacturer. When selecting linear measuring systems pleaseobserve that this system uses sinusoidal instead of rectangularoutput signals. With sinusoidal output signals, a significantly high‐er position resolution and better position accuracy is reached viaspecial evalutation revolution of our controllers. See also chapter9.21 "Position and velocity resolution" on page 128.

In the following you will find an incomplete list of manufacturers of suitablelength measuring systems for linear motors: Furthermore, other manufactur‐ers are available which cannot be listed all.

Bosch Rexroth AGLinear and assembly techni‐

que

Maria-Theresien-Straße 2397816 Lohr am Main, Germany

[email protected]://www.boschrexroth.com/business_units/brl/de/(Integrated measuring system for profiled rail guide)

Tab. 9-11: Manufacturers of length measuring systems

9.16 Braking systems and holding devicesThe following systems can be used as braking systems and/or holding devi‐ces for linear motors:● External braking devices● Clamping elements for linear guides● Holding brakes integrated in the weight compensation

Further designs about stand-still of linear motors are given inchapter 9.17 "End position shock absorber " on page 123 andchapter 9.20 "Deactivation upon EMERGENCY STOP and in theevent of a malfunction " on page 125 as well as in the appropri‐ate functional description of the drive controller.

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9.17 End position shock absorber

Damage on machine or motor componentswhen driving against hard stop!

WARNING

⇒ Use suitable energy-absorbing end position shock absorber⇒ Adhere to the specified maximum decelerations

Suitable energy-absorbing end position shock absorber must be provided inorder to protect the machine during uncontrolled coasting of an axis.If the maximum deceleration is exceeded, this can cause the primary part tocome loose and damage the engine components.

● When moving against a fixed stop, the maximum permissibledeceleration must be limited to 250 m/s² by a suitable ener‐gy-absorbing end position damper.

● The necessary spring excursion of the shock absorbersmust be taken into account when the end position shock ab‐sorbers are integrated into the machine (in particular whenthe total travel length is determined).

9.18 Axis cover systemsDepending on the application, design, operational principle and features ofsynchronous linear motors, the following requirements on axis cover systemsapply:● High dynamic properties (no overshoot, little masses)● Accuracy and smooth run● Protection of motor components against chips, dust and foreign objects

(in particular ferromagnetic parts),● Resistance to oil and coolant lubricants● Robustness and wear resistanceDifferent covering systems can be used, like bellow covers, telescopic coversor roller covers. A suitable axis cover system should be configured, if possi‐ble, during the early development process of the machine or system – sup‐ported by the corresponding specialized supplier.

9.19 Motor control and regulation9.19.1 General

The following figures shows a complete linear direct drive, consisting of asynchronous linear motor, length scale system, drive controller and superor‐dinate control.




Fig. 9-29: Linear direct drive

9.19.2 Drive controllersFor MCL motor control, different digital drive controllers and power supplymodules are available. (see chapter 10 "Motor-control combinations" onpage 133).

9.19.3 Control systemsA master control is required for generating defined movements. Dependingon the functionality of the whole machine and the used control systems,Bosch Rexroth offers different control systems..

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9.20 Deactivation upon EMERGENCY STOP and in the event of amalfunction

9.20.1 GeneralDeactivation of an axis equipped with MCL motor, can be initiated by● EMERGENCY STOP,● Drive fault (e.g. response of the encoder monitoring function) or● Power outage In the options for deactivation of MCL motors in case of malfunction, a dis‐tinction must be made between● Deactivation by the drive,● Deactivation by a master control and● Deactivation by a mechanical braking device.

9.20.2 Deactivation by the driveAs long as there is no fault or malfunction in the drive system, shutdown bythe drive is possible. The shutdown possibilities depend on the occurred driveerror and on the selected error response of the drive. Certain faults (interfacefaults or fatal faults) lead to a force disconnection of the drive.

Death, serious injuries or damage to equip‐ment may result from an uncontrolled coast‐ing of a switched-off linear drive!

WARNING

⇒ Construction and design according to the safety standards⇒ Protection of people by suitable barriers and enclosures⇒ Using external mechanical braking facilities⇒ Use suitable energy-absorbing end position shock absorber

The parameter values of the drive response to interface faults and non-fatalfaults can be selected. The drive switches off at the end of each fault re‐sponse.The following fault responses can be selected:0 – Setting velocity command value to zero1 - Setting force command value to zero2 - Setting velocity command value to zero with command value ramp and fil‐ter3 - Retraction

Please refer to the corresponding firmware function descriptionfor additional information about the reaction to faults and the rela‐ted parameter value assignments.




9.20.3 Deactivation by a master controlDeactivation by control functions

Deactivation by the master control should be performed in the followingsteps:

1. The machine PLC or the machine I/O level reports the fault to the CNCcontrol

2. The CNC control deactivates the drives via a ramp in the fastest possi‐ble way

3. The CNC control causes the power at the power supply module to beshut down.

Drive initiated via the control shutdownDeactivation via means of drive functions should be performed in the follow‐ing steps:

1. The machine I/O level reports the fault to the CNC control and SPS2. The CNC control or the PLC resets the controller enabling signal of the

drives. If SERCOS interface is used, it deactivates the ”E-STOP” inputat the SERCOS interface module.

3. The drive responds with the selected error response.4. The power at the power supply module must be switched off 500 ms af‐

ter the controller enabling signal has been reset or the ”E-Stop” inputhas been deactivated.

The delayed power shutdown ensures the safe shutdown of thedrive by the drive controller. With an undelayed power shutdown,the drive coasts in an uncontrolled way once the DC bus energyhas been used up.

9.20.4 Deactivation via mechanical braking deviceShutdown by mechanical braking devices should be activated simultaneouslywith switching off the power at the power supply module. Integration into theholding brake control of the drive controllers is possible, too. The followingmust be observed:● Braking devices with electrical 24V DC control (electrically-released)

and currents < 2 A can directly be triggered.● Braking devices with electrical 24V DC control and currents > 2 A can

be triggered via a suitable protection.Once the controller enabling signal has been removed, the holding brakecontrol has the following effect:● Fault reaction ”0”, ”1” and ”3”.

The holding brake control drops to 0 V once the velocity is less than 10mm/min or a time of 400 ms has elapsed.

● Fault reaction "2":The holding brake control drops to 0 V immediately after the drive ena‐bling signal has been removed.

9.20.5 Response to a power outageIn order to be able to shut down the linear drive as fast as possible in theevent of a power outage,

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● either an interruption-free power supply or● additional DC bus capacities (capacitors), and /or● mechanical braking facilitiesmust be provided.

Determining the required addition‐al DC bus capacity

Additional capacities in the DC bus represent an additional energy store thatcan supply the brake energy required in the event of a power outage.

The control voltage must be available even at a power failure forthe time of braking! If needed, buffer the control voltage supply orfeed the control voltage from the DC intermediate circuit if possi‐ble!

The additional capacity required for a deactivation upon a mains failure canbe determined as follows:

Cadd Required additional DC bus capacitor in mFm Moved mass in kgvmax Maximum velocity in m/sUDCmax Maximum DC bus voltage in VUDCmin Minimum DC bus voltage in VFmax Maximum braking force of the motor in NkFN Motor constant (force constant) in N/AR12 Winding resistance at 20 °CFR Friction force in NFig. 9-30: Determining the required additional DC bus capacitorPrerequisites:- final velocity = 0- velocity-independent friction- constant deceleration- winding temperature 135 °C

The maximum possible DC bus capacity of the employed powersupply module must be taken into account when additional ca‐pacities are used in the DC bus. Do not initiate a DC voltageshort-circuit when additional capacitors are employed.




9.20.6 Short-circuit of DC busMost of the power supply modules of Bosch Rexroth permit the DC bus to beshortened when the power is switched off, which also establishes a short-cir‐cuit between the motor phases. When the motor moves, this causes a brak‐ing effect according to the principle of induction; thereby the motor phasesare short-circuited. However, the achievable braking force is not very highand also depends on the velocity. The DC bus short-circuit can therefore onlybe used to support existing mechanical braking devices.

9.21 Position and velocity resolution9.21.1 Drive internal position resolution and position accuracy

In linear direct drives, a linear scale is used for measuring the position. Thelinear scale for linear motors supply sinusoidal output signals. The length ofsuch a sine signal is known as the signal period. It is mainly specified in mmor µm.With the drive controllers from Bosch Rexroth, the sine signals are amplifiedagain in the drive (see Fig.9-32). The drive-internal amplification also de‐pends on the maximum travel area and the signal period of the length meas‐uring system. It always employs 2n grid points (e.g. 2048 or 4096).

fint Multiplication factor (S-0-0256, Multiplication 1)sp Linear scale system signal period in mm (S-0-0116 Resolution

of encoder 1)xmax Maximum travel (S-0-0278, Maximum travel)Fig. 9-31: Multiplication factor

Fig. 9-32: Drive-internal multiplication and/or interpolation of the measuringsystem signals

With a known signal period and a drive-internal multiplication, the drive-inter‐nal position resolution results as:

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Δxd Drive-internal position resolutionsp Linear scale system signal period (S-0-0116 Resolution of en‐

coder 1)fint Multiplication factor (S-0-0256, Multiplication 1)Fig. 9-33: Drive-internal position resolution

The drive-internal position resolution is not identical to the reacha‐ble positioning accuracy.

Reachable positioning accuracy The reachable position accuracy depends on the mechanical and control-en‐gineering total system and is not identical to the drive-internal position resolu‐tion.The reachable position accuracy can be estimated as follows (using empiricalvalues):

Δxd Drive-internal position resolutionΔxabs Position accuracyFig. 9-34: Estimating the reachable position accuracyPrerequisites: Optimum controller setting

The expected position accuracy cannot be better than the small‐est position command increment of the superordinate control.

9.21.2 Velocity resolutionThe resolution of the velocity is proportional to the position resolution (see fig.9-33 "Drive-internal position resolution" on page 129) and inversely propor‐tional to the cycle rate tAD from:

Δvd Velocity resolution in m/sΔxd Drive-internal position resolutiontAD Cycle rate in s (IndraDrive: Basic performance 250 µs /

Advanced 125 µs)Fig. 9-35: Velocity resolution

9.22 Thermal connection - Installation modesAn effective heat loss dissipation is a prerequisite for achieving the specifiedmotor data. The amount of heat loss in the motor is largely determined by theutilization rate of the motor. How well or how quickly the heat loss can be dis‐sipated determines the performance of the motor.If the heat of the motor cannot be sufficiently dissipated by means of naturalconvection, the heat introduction via the contact surfaces into the machineconstruction is increased. Particularly high heat dissipation is achieved if the




contact surfaces of the primary and secondary parts are combined with ahighly heat-dissipating machine construction.In this connection, please observe that an increased heat introduction intothe machine construction has a negative impact on the achievable accuracy.During design of a system with maximum accuracy, the operating tempera‐ture of the motor winding is decisive.With increasing winding temperature, the emitted heat of the machine is alsoincreased. If the temperature level of the machine has to be kept at a con‐stant level, the motor should be sufficiently dimensioned or equipped withmachine-side cooling.

If the contact surfaces of the motor components, particularly ofthe primary part, are made of a material with low heat conductivity(e.g. plastic), a reduction in motor performance has to be expec‐ted.In general, the heat dissipation must be increased proportionallywith the size and frame length and the respectively higher powerloss of the motor if the same utilization capacity of the motor is tobe achieved.For this reason, observe maximum heat dissipation of motor com‐ponents when designing the machine. Only this way optimum dis‐sipation of the emitted heat of the motor via the surrounding ma‐chine components can be ensured.

The following specifications serve as reference to estimate the required mo‐tor performance data depending on the thermal connection of the motor. Theillustrated installation modes can be selected and taken into account for mo‐tor controller dimensioning in IndraSize and for commissioning in IndraWorks.

① Available motor force② Installation modeFig. 9-36: Motor force dependent on thermal connection

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Explanation of installation modes

Installationmode Schematic illustration Description

A

Installation mode A requires good thermal connection of the motor in com‐bination with additional cooling, e.g. by using a fan or by cooling the con‐tact surfaces. Regarding the structure of the contact surfaces at the ma‐chine, a metal surface with high conductivity is required.

B

Installation mode B requires good thermal connection of the motor to themachine. Regarding the structure of the contact surfaces at the machine,a metal surface with high conductivity is required. The technical data forthis installation mode is specified in chapter 4 "Technical data" on page21.

C

Installation mode C assumes that a motor component (primary or secon‐dary part) is thermally isolated and the other components must be well-conductively connected to the machine. In this case, reckon with a per‐formance reduction of the motor due to moderate heat dissipation

D

Installation mode D assumes that both motor components (primary andsecondary part) are connected to the machine in a thermally isolated way.This mode of assembly is the worst case and it must be reckoned with asignificant disability of the motor.

Tab. 9-12: Explanation of installation modes




9.23 Operation at or near motor standstillIn the motor is to be operated at standstill or close to standstill, special condi‐tions apply. For means of simplification, this operation is indicated as stand‐still operation in the following. The absolute standstill operation is marked bythe following aspects:● The duration of the standstill operation is longer than 10 % of the re‐

spective thermal time constant Tth

● Motor does not move● Motor performs only very small strokes (≤ 2 * Τp)● Motor moves only at very low frequency (f ≤ 0.1 Hz)Due to the 3-phase system, during standstill operation in one of the threephases there is always an instantaneous value of the current, the amount ofwhich is higher than the permissible continuous current. Does the currentflow continuously, the motor will overheat and be thermally damaged. Alsorefer to chapter 9.10 "Motor temperature monitoring" on page 107). Thepeak value of the instantaneous current is equal with the amplitude of the si‐nusoidal assumed phase current. Its value is higher by root 2 than the effec‐tive value of the continuous current (IN). The power loss PV, created in thecoil, is calculated using

Δθ Temperature difference between operation temperature and20 °C

αCu Temperature coefficient of the specific resistance of copper =0.0039 Ohm * m / mm²

Fig. 9-37: Power loss coilFor the nominal current, a double power loss occurs in the affected coil.To avoid damaged winding in standstill operation, limit the current or the op‐eration duration. A possible form of an additional motor protection is the limi‐tation of the motor current to 87% of the nominal current.

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10 Motor-control combinations10.1 General

The technical data and the figure of the motor characteristics of several mo‐tors is displayed inchapter 4 "Technical data" on page 21.

A dimensioning and selection of individual motors must be donein Gantry arrangement.

Maximum allowed intermediatecircuit.

Frame size dependend maximum DC bus voltages for MCL motors are de‐fined. Please also observe the information provided under tab. 4-1 "Generaltechnical data" on page 27.

Exceeding of voltage limits!DANGER

Prepare a suitable connection with a protective switch via the primary partcarrier when using AC voltage > 50 V or DC > 120 V (DIN IEC 60364-4-41)for MCP015.

10.2 Motor-control combinations with NYCe 4000

NYCe 4120 NYCe 4140

48 V 72 V 150 V

MCP015A-L040MCP015B-L040

■ ■ -

MCP020x-Vxxx x x

MCP030x-Vxxx x x

MCP040x-Vxxx x x

MCP070x-Vxxx x x

■ optimum combinationx permitted combination - reduced velocity, as DC bus voltage is

reduced in relation to nominal voltage.- Combination not permittedTab. 10-1: Motor-control combinations with NYCe 4000


Motor-control combinations


10.3 Motor-control combinations with IndraDrive Cs

HCS01.1E-Wxxxx-A-02-... HCS01.1E-Wxxxx-A-03-...

3x AC 110 ... 230 V / 1x AC 110 ... 230 V 3x AC 200 ... 230 V

W003 W006 W009 W013 W018 W005 W008 W018 W028 W054

Power cables RKL4800 RKL4801 RKL4800 RKL4801 RKL4803

MC

P020

020B-V180 ■ □

020B-V720 ■ x □

020C-V180 ■ x □

020C-V720 ■ x □

020D-V180 ■ □

020D-V720 x ■ □

MC

P030

030B-V180 ■ x □

030B-V390 x ■ □

030C-V180 ■ □

030C-V390 x ■ □

030D-V180 ■ □

030D-V390 x ■ □

MC

P040

040B-V070 ■ □

040B-V300 ■ □

040C-V070 x ■ □

040C-V300 ■ □

040E-V070 ■ □

040E-V300 x x ■

040G-V070 ■ □

040G-V300 ■

MC

P070

070C-V050 ■ x □

070C-V300 x x ■

070D-V050 ■ □

070D-V300 ■

070F-V050 x x ■

070F-V300 x ■

070M-V050 x ■

070M-V230 x

■ optimum combination□ permitted combinationx permitted combination - maximum force, however, reduced, as

the controller is under-dimensioned.Tab. 10-2: Motor-control combination with IndraDrive Cs

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Motor-control combinations



11 Motor dimensioning11.1 General procedure

Linear drive dimensioning is determined by the application-dependent char‐acteristics of velocity and feed force and from the thermal connection. Thesequence of dimensioning of linear drives is illustrated by the following figure.

Fig. 11-1: General procedure of linear drives dimension


Motor dimensioning


11.2 Basic formulae11.2.1 General movement equations

The variables required for sizing and selecting the motor are calculated usingthe equations shown in the following.

The process-related feed forces and speeds are used directly fordrive selection during project planning of linear direct drives with‐out conversions.

v(t) Velocity profile over time in m/ss(t) Distance course over time in ma(t) Acceleration profile vs. time in m/s²F(t) Force course over time in Nm Moved mass in kgF0(t) Base force and friction in NFP(t) Processing force or operation force in NFeff Effective force in Nvavg Average velocity in m/st Time in sT Total time in sFig. 11-2: General equations of motionIn most cases the mathematical description of the required positions vs. thetime is known (NC-program, electronic cam disk). By means of path function,the calculation of velocity, acceleration and force can be done. Standard soft‐ware (such as MS Excel or MathCad) can be used for calculating the re‐quired variables, even with complex motion profiles.

The following chapter provides a more detailed correlation for tra‐pezoidal, triangular or sinusoidal speed curves.

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Motor dimensioning



11.2.2 Feed forces

Fig. 11-3: Determining feed forces

FACC Acceleration force in NFW Weight force in NFF Friction force in NF0 Additional friction or base force in N (e.g. due to sealings of lin‐

ear guides)FMAX Maximum force in NFEFF Effective force in NFP Processing force in Na Acceleration in m/s²m Moved mass in kgg Final velocity (9,81 m/s²)α Axis angel in degrees (0°: horizontal axis; 90°C: vertical axis)fCB Weight compensation in %tall Total duty cycle time in sFATT Attractive force between primary and secondary part in Nµ Friction coefficientFig. 11-4: Determining feed forces


Motor dimensioning


For dimensioning of linear motor drives, take the moving mass ofthe motor components into consideration (in particular in case oflow load inertia). However, the moving mass is only known afterthe motor has been selected. For this reason, an assumptionmust first be made and checked again after the motor has beenselected.

Fig. 11-5: Determining resulting feed forces, dependend from the mode of mo‐tion and direction.

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Motor dimensioning



F Resulting force in NFACC Acceleration force in NFW Weight force in NFF Friction force in NFig. 11-6: Determining resulting feed forces, dependend from the mode of mo‐

tion and direction.

With horizontal axis arrangement, the weight is FW = 0. Further di‐rection-dependend base and process forces must be additionallyobserved.


Motor dimensioning


11.2.3 Average velocityThe mean velocity is required to determine the mechanic continuous powerof the drive. The generally valid determination of the average velocity isspecified in fig. 11-2 "General equations of motion" on page 136. The follow‐ing calculation can be used for a user-friendly determination of trapezoidal ortriangular speed profiles:

Fig. 11-7: Triangular or trapezoidal velocity profile

vavgi Average velocity for a velocity segment with a duration ti in m/sva Initial velocity of the velocity segment in m/sve Final velocity of the velocity segment in m/svavg Average velocity over total cycle duration in m/sti Duration velocity segment in stall Total duty cycle time, including breaks and/or standstill time, in

sFig. 11-8: Determining the mean velocity of triangular or trapezoidal speed pro‐

files

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Motor dimensioning



11.2.4 Trapezoidal velocity profileGeneral

This mode of operation is characteristic for the most applications. After a con‐stant acceleration phase, a motion with constant velocity up to braking phasewith constant delay follows.

Fig. 11-9: Trapezoidal velocity profileWhen determining the respective parameters acceleration a, velocity v, dis‐placement s and time t for trapezoidal travel, a case distinction must be madewith regard to velocity:● Initial velocity va = 0 or va <> 0● Final velocity ve = 0 or ve <> 0

Acceleration, initial velocity va= 0

● Velocity v ≠ constant● Initial velocity va = 0● Acceleration a = constant and positive


Motor dimensioning


a Acceleration in m/s²vc Final velocity in m/sta Acceleration time in ss Distance during acceleration in mFig. 11-10: Constantly accelerated movement, initial velocity va= 0 (for trapezoi‐

dal velocity profile)

Acceleration, initial velocity va= 0

● Velocity v ≠ constant● Initial velocity va ≠ 0● Acceleration a = constant and positive

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Motor dimensioning



a Acceleration in m/s²vc Final velocity in m/sva Initial velocity in m/sta Acceleration time in ss Distance during acceleration in mFig. 11-11: Constantly accelerated movement, initial velocity va= 0 (for trapezoi‐


Constant velocity

● Velocity v =constant● Acceleration a = 0

vc Constant velocity in m/stc Time during constant velocity in ssc Distance during constant velocity in mFig. 11-12: Constant velocity (for trapezoidal velocity profile)

Brakes, final velocity ve= 0

● Velocity v ≠ constant● Final velocity ve = 0● Acceleration a = constant and negative


Motor dimensioning


a Acceleration in m/s²vc Final velocity in m/stb Braking time in ss Distance during deceleration in mFig. 11-13: Constantly decelerated movement, final velocity ve= 0 (for trapezoi‐


Brakes, final velocity ve= 0

● Velocity v ≠ constant● Final velocity ve ≠ 0● Acceleration a = constant and negative

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Motor dimensioning



a Acceleration in m/s²vc Initial velocity in m/sve Final velocity in m/stb Braking time in ss Distance during deceleration in mFig. 11-14: Constantly decelerated movement, final velocity ve= 0 (for trapezoi‐


11.2.5 Trapezoidal velocity profileThis velocity profile has no phase of constant velocity in contrast to trapezoi‐dal profiles. The acceleration phase is immediately followed by the decelera‐tion phase. This process is frequently encountered with short-stroke move‐ments.

Fig. 11-15: Trapezoidal velocity profile.


Motor dimensioning


vmax Maximum reachable velocity in m/sa Acceleration in m/s²sall Total travel path in mt Positioning time in sFig. 11-16: Calculation of triangular velocity profile

11.2.6 Sinusoidal velocity profileThis velocity characteristic results, for example, from circular interpolation oftwo axes (circular movement) or from the oscillating movement of one axis,e.g. during grinding.The specified variables are chiefly the motion travel s or the circle diameter 2rand the period duration T.

Fig. 11-17: Insert distance and velocity of an axis at sinusoidal velocity

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Motor dimensioning



s(t) Chronological course of distancer1 Radiusr(t) Chronological course of velocityt Timea(t) Accelerationω Circular frequencyT Period durationf FrequencyFig. 11-18: Calculation formular for distance and velocity of an axis for sinusoi‐

dal velocityBy means of fig. 11-17 "Insert distance and velocity of an axis at sinusoidalvelocity" on page 146 and fig. 11-18 "Calculation formular for distance andvelocity of an axis for sinusoidal velocity" on page 147 results in the followingcalculation base:


Motor dimensioning


amax Maximum acceleration in m/s²vmax Maximum velocity in m/sr Travel length in one direction or radius in mT Period duration in sm Moved mass in kgFACC Acceleration force in NFEFF Effective force in NFEFFv Effective force at vertical or inclined axis arrangement in NF0 Base force, e.g. friction, in NFW Weight force in NFig. 11-19: Calculation formula for sinusoidal velocity profile

Further direction-dependend base and process forces must beadditionally observed.

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Motor dimensioning



11.3 Duty cycle and feed force11.3.1 General

The relative duty cycle ED specifies the duty cycle percentage of the loadwith respect to a total duty cycle time, including idle time. The thermal loadcapacity of the motor limits the duty cycle. Loading the motor with a continu‐ous nominal force is possible during the entire duty cycle time. To avoid ther‐mal overload at motors with higher feed forces reduce the duty cycle at F >FdN (see fig. 11-20 "Correlation between duty cycle and feed force." on page149).

Fig. 11-20: Correlation between duty cycle and feed force.

11.3.2 Determining the duty cycleDue to the linear correlation of force and current, the approximate determina‐tion of the relative duty cycle EDideal is performed via the correlation:

EDideal Cyclic duration factor in %FEFF Effective force or continuous force in NFMAX Maximum feed forceFig. 11-21: Approximate determination of duty cycle EDDetermination of possible relative duty cycle can done with the help of fig.11-22 "Determining the duty cycle ED" on page 150.


Motor dimensioning


EDreal Possible relative duty cycle in %PvN Maximum heat dissipation of the motor in W (for continuous

power loss see chapter 4 “Technical data”).PAVG a Average motor power loss in application over a duty cycle time

including idle time in WFig. 11-22: Determining the duty cycle ED

11.4 Determining the drive power11.4.1 General

To size the power supply module or the mains rating, you must determine therated (continuous) and maximum power of the linear drive.

Take the corresponding simultaneity factor into account when de‐termine the total power of several drives that are connected to asingle power supply module.

11.4.2 Continuous powerThe continuous power corresponds to the sum of the mechanical and electri‐cal motor power.

Pc Continuous power in WPcm Mechanical continuous power in WPV Electrical continuous power loss of motor in WFeff Effective force in N (from application)vavg Average velocity in m/sFN Rated force of the motor in N (see chapter 4 ”Technical data”)PVN Rated power loss of the motor in W (see chapter 4 ”Technical

data”)Fig. 11-23: Continuous power of the linear motor

When reducing the continuous nominal force, the electric continu‐ous power is also reduced (seefig. 11-23 "Continuous power ofthe linear motor" on page 150).

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Motor dimensioning



11.4.3 Maximum outputThe maximum output is also the sum of the mechanical and electrical maxi‐mum output. It must be made available to the drive during acceleration anddeceleration phase or for very high machining forces, for example.

Pmax Total maximum power in WPmaxm Mechanical maximum power in WPmaxe Electrical maximum power in W (see the following diagram)Fmax Maximum feed force in NvFmax Maximum velocity with Fmax in NFig. 11-24: Maximum power of the linear motor

If the maximum feed force is reduced in relation to the achievablemaximum force of the motor, the maximum electrical power is al‐so reduced Pmaxe. To determine the reduced electrical maximumoutput Pmaxe, use fig. 11-25 "Diagram used for determining the re‐duced electrical power loss" on page 151.

Fmax Maximum force motor in NF Maximum force application in NPVmax Maximum power loss of the motor in WPV Power loss of motor application in WFig. 11-25: Diagram used for determining the reduced electrical power loss


Motor dimensioning


11.4.4 Power lossThe power loss corresponds to the continuous electrical power loss of themotor.

PV Electrical power loss of motor in WFeff Effective force in NFN Rated force of the motor in N (see chapter 4 ”Technical data”)PvN Rated power loss of the motor in W (see chapter 4 ”Technical

data”)Fig. 11-26: Required cooling capacity of the linear motor

11.5 Energy regenerationCompared with rotary servomotors, the energy of a linear motor during decel‐eration is lower. The translational velocity of a linear motor is usually muchlower than the circumferential speed of a rotary servomotor.The regenerative power of a synchronous linear drive results from the energybalance during braking and can be estimated as follows for dimensioning ad‐ditional braking resistors or regenerative supply units:

PR Energy regeneration during a braking phase in WPRavg Average energy regeneration over total cycle duration in Wm Moved mass in kgv Maximum velocity in m/stb Braking time in sFR Friction force in NR12 Winding resistance of the motor at 20°C in Ohm (see Chapter

4 “Technical data”)amax Brake retardation (negative acceleration) in m/s²kiFN Motor constant in N/Atall Total cycle duration in sFig. 11-27: Energy regeneration of linear motor Prerequisites: Velocity-independent friction

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Motor dimensioning



Constant decelerationFinal velocity = 0

If the determined regenerative power according to Fig. 11-27 isnegative, no energy is fed back, i.e. energy must be supplied tothe motor during braking.

11.6 EfficiencyThe efficiency of electrical machines is the ratio between output and inputpower and, in the case of linear motors, is determined by the application-de‐pendent travel speeds and forces and the corresponding motor losses.The motor efficiency can be determined or estimated with the help of fig.11-28 "Efficiency determination for linear motors" on page 153.

η EfficiencyPmech Mechanical power in WPV Power loss in WF Feed force in Nv Velocity in m/sFig. 11-28: Efficiency determination for linear motors


Motor dimensioning


12 Handling, transport and storage12.1 Delivery status and packaging12.1.1 Primary parts

The primary parts are packaged in a box. For identification, the package ismarked with a label with the type designation of the primary part.

12.1.2 Secondary partsThe secondary parts are individually packaged in a box. For identification, thepackage is marked with a label with the type designation of the secondarypart.

Warning notes on the package ofthe secondary parts

A self-adhesive warning note is on the packaging of the secondary parts witha warning about danger after opening the package and resulting handling ofthe secondary parts.

Fig. 12-1: Warning label on the package of secondary parts

The self-adhesive warning label (dimensions approx. 110 mm x150 mm) can be ordered from Rexroth (MNR R911278745) forthe user's own purposes.

12.2 Testing of motor components12.2.1 Factory checks of the motor components

Electrical testing During manufacturing, the following electrical tests are performed at linearmotors of Bosch Rexroth:● High voltage test according to DIN EN 60034-1● Insulation resistance testing according to DIN EN 60204-1● Testing for compliance with electrical characteristics


Handling, transport and storage


Mechanical testing Linear motor components of Bosch Rexroth are subject to the following me‐chanical testing:● Shape and position tolerance according to DIN ISO 1101● Construction and fitting according to DIN 7157● Surface structure according to DIN ISO1302● Thread testing DIN 13 part 20

Destruction of motor components due to im‐properly executed high-voltage testing! Lossof warranty!

CAUTION

⇒ Avoid repeated testing.⇒ Comply with the guidelines of DIN EN 60034-1

EMC radio interference suppres‐sion

Linear motor components of Bosch Rexroth have been subject to EMC typetesting and are certified for complianceEN 55011 Limit Class B, VDE 0875 Part 11

12.3 Transport and storage12.3.1 Notes about transport

Our products must be transported in their original package only. Also refer tothe specific ambient factors to protect the products from transport damage.

Risk of injuries and / or damage when usingsecondary parts!

CAUTION

The inside of the secondary parts is laminated with permanent magnets.Make sure that no small ferromagnetic parts like screws get into contact withthe air gap. Also observe the warning notes in fig. 12-1 "Warning label on thepackage of secondary parts" on page 155.

Based on DIN EN 60721-3-2, the tables below specify classifications and lim‐it values which are allowed for our products while they are transported byland, sea or air. Refer to the detailed description of the classifications to takeall of the factors which are specified in the particular class into account.Allowed classes of environmental conditions during transport acc. to DIN EN60721-3-2

Classification type Allowed class



Classification of chemically active materials 2C1



Tab. 12-1: Allowed classes of environmental conditions during transportFor a better overview, some essential environmental influencing variables ofthe previously mentioned classifications are listed. Unless otherwise speci‐fied, the specified values are the values of the particular class. However,

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Bosch Rexroth reserves the right to adjust these values at any time based onfuture experiences or changed environmental factors.Deviating from DIN EN 60721-3-2 permissible ambient conditions


Temperature °C -25 ... +701)

Relative air humidity % 5 ... 751)

Absolute air humidity g/m³ 1 ... 291)

1) Differs from DIN EN 60721-3-2Tab. 12-2: Deviating permissible storage conditions

Air freight Possible influence of plane electronic onboard through magnet fields!

CAUTION

⇒ Heed the packaging and transport instructions (IATA 953)

12.3.2 Information on storageStorage conditions

Generally, Bosch Rexroth recommends storing all components until they areactually installed in the machine as follows:● in their original packaging● at a dry and dust-free location● at room temperature● free from vibrations and oscillations● protected against light or direct sunlightUpon delivery, protective sleeves and covers can be attached to BoschRexroth motors. They have to remain on the motor for transport and storage.Do not remove these parts until shortly before assembly.Based on DIN EN 60721-3-1, the tables below specify classifications and lim‐it values which are allowed for our products while they are stored. Refer tothe detailed description of the classifications to take all of the factors whichare specified in the particular classification into account.Allowed classes of ambient conditions during storage acc. to DIN EN60721-3-1

Classification type Class



Classification of chemically active materials 1C1



Tab. 12-3: Allowed classes of environmental conditions during storageFor a better overview, some essential environmental influencing variables ofthe previously mentioned classifications are listed. Unless otherwise speci‐fied, the specified values are the values of the particular class. However,Bosch Rexroth reserves the right to adjust these values at any time based onfuture experiences or changed environmental factors.




Deviating from DIN EN 60721-3-1 permissible ambient conditions


Air temperature °C -25 ... +551)

Relative air humidity % 5 ... 751)

Absolute air humidity g/m³ 1 ... 291)

1) Differs from DIN EN 60721-3-1Tab. 12-4: Deviating permissible storage conditions

Storage timesAdditional measures have to be taken upon commissioning to ensure smoothfunctioning – irrespective of the storage time which may be longer than thewarranty period of our products. However, this does not entail any additionalwarranty claims.

Motors Storage time Measures for commissioning

< 1 year Visual inspection of all parts to be damage-freeCheck the electric contacts to verify that they are free fromcorrosion

1 ... 5 years

> 5 years

Tab. 12-5: Measures before commissioning motors that have been stored overa prolonged period of time

Cable and plug connector Storage time Measures prior to commissioning

< 1 year None

1 ... 5 years Check the electric contacts to verify that they are free fromcorrosion

> 5 yearsIf the cable or the cable jacket has porous parts, replace it;otherwise check the electric contacts to verify that they arefree from corrosion

Tab. 12-6: Measures before commissioning of cables and connectors that havebeen stored over longer periods of time

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13 Assembly13.1 Basic precondition

The following points must be considered or checked before starting the as‐sembly work:● Observe of the necessary installation sizes (see chapter 5.1 "Specifica‐

tions" on page 45)● Machine construction fulfills the requests for mounting (stiffness, attrac‐

tive force, feed and acceleration force, etc.) and is prepared for installa‐tion of the motor components.

● Clean screw-on surfaces between machine and motor components● Installation of motor components by skilled personnel only● Compliance of danger and safety notes is guaranteed.

13.2 Arrangement of motor componentsDuring machine planning, observe and specify the position of the motor com‐ponents in the machine. All fixtures and screw-on surfaces must be preparedfrom the machine manufacturer for installation of the motor components.Basically, no limitations about arrangement of the motor components exists.It can be an advantage to mount the secondary part sidewards (see fig. 13-1"Arrangement of motor components within ready-to-mount compact moduleCKL of Rexroth" on page 159) or downwards toppled that dirt, residuesa.s.o. can drop into the air gap between primary and secondary part fromabove. In this content, please observe the notes under chapter 9.12.4 "Pro‐tection of the motor installation space" on page 112 on how the installationspace must be created to optimally protect the motor components. The fol‐lowing figure shows a possible motor assembly. Dependend from the applica‐tion, another arrangement can be preferred.

① Secondary part MCS ...② Primary part MCP③ Measurement system④ Machine slide⑤ Guidances / profile railsFig. 13-1: Arrangement of motor components within ready-to-mount compact

module CKL of Rexroth


Assembly


13.3 Installation of motor componentsThe order of installation of motor components is depending on the machineconstruction or the available space in the machine. Also, the arrangement ofthe motor components plays a significant role.In the following assembly example, always motor setup in single arrangementis assumed.● Possibility A

First, determine the secondary parts. Then, insert the primary part later‐ally into the secondary parts and fasten it on the machine. MCP015 pri‐mary parts can also be mounted from above into the secondary part dueto their design (T-shape).

● Possibility BInitially assemble only one secondary part. Insert the primary part on thefront side (or MCP015 from above) into the secondary part and fasten iton the machine. Then, mount the remaining secondary parts.

● Possibility CFirst, mount the primary part and afterwards the secondary part.

13.4 Air-gap, parallelism and symmetry of the motor componentsParallelism and symmetry When mounting primary and secondary parts, their position is specified by

the holes or threads within the machine slide and within the machine bed.Due to the clearance, which exists within the holes of the screw connections,the motor components must be adjusted correctly acc. to fig. 13-2 "Aligningthe motor components" on page 160 before the screws are tightened. Thiscan be done via pressing the motor components on the screw-on surfacesand stop faces. If all installation dimensions tab. 5-1 "MCL015 Installation di‐mensions and tolerances" on page 46Installation dimensionstab. 5-2 "Instal‐lation dimensions and tolerances MCL020 ... 070" on page 47were adheredto, the correct arrangement of both motor components to each other results.

① Secondary part② Primary partFig. 13-2: Aligning the motor components

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Assembly



Air gap Motor damage due to insufficient air gap be‐tween primary and secondary part!

NOTICE

After assembly, check the free movement of the motor components to eachother immediately. Therefore, move the versatile motor components by handover the complete travel length. The versatile motor components must befreely movable at each position over the total travel length - without any con‐tact to fixed motor components. This check can detect faulty assembly in time(e.g. dirt under the assembly surfaces, faulty installation dimensions, insuffi‐cient machine rigidity etc.).

13.5 Fastening secondary partObserve absolute cleanness during assembly. No dirt should exist on thescrew-on surface and stop faces and no dirt or other parts (e.g. screws,washers, etc.) should reach the area of magnetic pull on the secondary part.Any kind of foreign bodies in this area could damage the primary or secon‐dary part at the first traverse of the motor components.

● For safety reasons, the user or machine manufacturer isNOT allowed to dismount the secondary part in its separateparts!

● To fasten the secondary parts, it is only allowed to use new,unused screws.

● After aligning, tighten all screws with the specified tighteningtorque (seeChapter 13.4 ). Additionally secure the screwconnection with Loctite 243.

● After assembly, check if any foreign bodies exist in the sec‐ondary part.

The secondary parts can be connected with the machine via two differentways.

① Fastening type variant 1② Fastening type variant 2Fig. 13-3: Secondary part fastening types The screw-on surfaces and stop faces must be cleaned and be free of greasebefore the secondary parts can be screwed on the machine construction. Forsuitable screw selection and its tightening torques refer to the following table.


Assembly


Motor damage due to insufficient air gap be‐tween primary and secondary part!

NOTICE

Observe during fastening of the secondary parts according to variant 2 thatthe maximum screw-in depth specified in the table, is kept. In the case of de‐fiance, the primary part can be irreparably damaged due to collision withoverhanging screws.

Fastening type - variant 1

Secondarypart MCS ...

Drilling diam‐eter withinthe secon‐dary part

maximumscrew-in depth

Screw size(DIN EN ISO

4762)Fastening class

Tightening torque(+/-10%)

Variant 1

015 4.5 mm

depending from the customer´sapplication

M4

8.8

3.1 Nm

020 4.3 mm M4 3.1 Nm

030 4.3 mm M4 3.1 Nm

040 6.4 mm M6 10.4 Nm

070 8.5 mm M8 25 Nm

Tab. 13-1: Fastening mode (variant 1) with tightening torques for MCS

Fastening type - variant 2

Secondarypart MCS ...

Thread di‐ameter with‐in secondary

part

maximumscrew-in depth

Screw size(DIN EN ISO

4762)Fastening class

Tightening torque(+/-10%)

Variant 2

015 M4 9 mm M4

8.8

3.1 Nm

020 M5 9 mm M5 6.1 Nm

030 M5 9 mm M5 6.1 Nm

040 M6 11 mm M6 10.4 Nm

070 M8 12 mm M8 25 Nm

Tab. 13-2: Fastening mode (variant 2) with tightening torques for MCSThe calculation about firmness of screw connection for fastening the secon‐dary part are based on the assumption that the screwing surface of the sec‐ondary part and the screwing surface of the machine are clean and the sec‐ondary part is screwed in direct contact with the machine and secured withLoctite 243.

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Assembly



● In certain cases it is not possible to screw the secondarypart with the machine directly, as additional materials likedistance plates, thermal grease and so on, are among sec‐ondary part and machine. Then a sufficient fastening of thescrew connection must be ensured by the machine manu‐facturer.

● The effect of liquid screw lock is damaged by loosening orre-tightening of screws (e.g. due to torque tests) and mustbe renewed.

● Use all fastening points to fasten the secondary part.

13.6 Fastening the primary part

① Fastening type variant 1② Fastening type variant 2Fig. 13-4: Primary part fastening type

Primarypart MCP ...

Screw size(DIN EN

ISO 4762)

Screw-in depth Fastening

class

Tighteningtorque

(+/-10%)Variant 1 Variant 2

015 M3

see chapter 5 "Dimen‐sion sheets" on page 45 8.8

1.3 Nm

020

M4 3.1 Nm030

040

070 M6 10.4 Nm

Tab. 13-3: Tightening torque for the fastening screws of the primary partsThe screw-on surfaces and stop faces must be cleaned and be free of greasebefore the primary parts can be screwed on the machine construction. Se‐cure all screwed connections with screw connection, e.g. Loctite 243.Mounting instructions:

1. Preparing the threades holes and screws for assembly2. Fasten the primary part with screws 1, 2, 3...n until the primary part lies

on the slide.Fasten screws - from inside to outside - 1, 2, 3 ... x with nominal tighten‐ing torque:


Assembly


Fig. 13-5: Tightening row of screws

● Use all fastening points to fasten the primary part.● The effect of liquid screw lock Loctite 243 is damaged by

loosening or re-tightening of screws (e.g. due to torquetests) and must be renewed.

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Assembly



13.7 Electrical connection Connect the motor electrically according to the connection diagrams and theinstructions in chapter 8 "Connection technique" on page 83. Refer to thereferences to supplementary documentation.

● When using self-manufactured cables, ensure EMC-compli‐ant design and installation.

● Where applicable, ensure that connectors and lines are fas‐tened for strain relief purposes.

● The connection diagrams of the product documentationserve to create system circuit diagrams. Only the machinemanufacturer's system wiring diagrams are relevant for theconnection of the drive components in the machine.


Assembly


14 Commissioning, operation and maintenance14.1 General

In some points, commissioning of linear motors is different in comparison torotary servo motors. For commissioning of synchronous linear motors, the fol‐lowing points must be observed in particular:

Parameters Synchronous linear motors are kit motors whose single components are di‐rectly installed into the machine by the manufacturer – completed by an en‐coder system. As a result, kit motors do not feature any data memory to pro‐vide motor parameters, standard controller settings, etc. All parameters mustbe manually entered or loaded to the drive during commissioning. TheIndraWorks commissioning program provides all Rexroth motor parameters.

Controller optimization The procedure for controller optimization (current, velocity and position con‐troller) at linear direct drives corresponds to the procedure for rotary servodrives. Only the setting limits of linear drives are higher. For example, this en‐ables setting up to 10 times higher kv factors at linear direct drives in compar‐ison to rotary servo drives. However, this requires a respective machine con‐struction (see chapter 9.12 "Requirements on the machine design" on page110).

Moving masses With controlled rotary servo drives, there are control limitations in the ratio ofmotor moment of inertia to load moment of inertia. This restriction does notapply for direct drives with linear motors: The moved external load dependson load of the motor itself.

Encoder polarity The polarity of the actual velocity (length measuring system) must complywith the force polarity of the motor. Before commutation adjustment, this rela‐tion must be established.

Commutation adjustment It is necessary at synchronous linear motors to receive the position of the pri‐mary part relating on the secondary part by return after start or after a mal‐function. This is referred to as pole position detection or commutation adjust‐ment. This means that the commutation adjustment is the establishment of aposition reference to the electrical or magnetic model of the motor. Commuta‐tion adjustment can only be made after installation of motor components andthe length measuring system. The commutation adjustment method dependson the measuring principle of the length measuring system.

14.2 General requirements 14.2.1 General

The following requirements have to be met to ensure successful commission‐ing:● Compliance with safety-related guidelines and instructions● Check of electrical and mechanical components for reliable functioning● Availability and provision of required tools● Adherence to the commissioning procedure described below

14.2.2 Checking all electrical and mechanical componentsCheck all electrical and mechanical components prior to commissioning andpay particular attention to the following issues:


Commissioning, operation and maintenance


● Ensure safety for man and machine● Correctly install the motor● Correct power connection of the motor● Connect connection of the length measuring system● Ensure proper function of existing safety limit switches, door

switches, etc.● Ensure correct function of the emergency stop circuit and

emergency stop.● Ensure proper and complete machine construction (mechan‐

ical installation)● Availability and function of suitable end position dampers● Ensure correct connection and function of drive controller

and control unit

14.2.3 ToolsIndraWorks commissioning soft‐

wareThe motors can be commissioned either directly via an NC terminal or viaspecial commissioning software. The IndraWorks commissioning software al‐lows menu-driven, custom-designed and motor-specific parameterization andoptimization.

PC For commissioning by means of IndraWorks, a conventional Windows PC isrequired.

Commissioning via NC Commissioning via the NC control unit requires access to all drive parame‐ters and functionalities.

Multimeter Troubleshooting and component checks can be facilitated by a multimeter al‐lowing the measurement of voltage, current and resistance values.

14.3 General commissioning procedureThe general commissioning sequence for MCL ironless synchronous linearmotors is explained in the following diagram. The individual items are ex‐plained in more detail in the chapters following thereafter.

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Fig. 14-1: General commissioning procedure for synchronous linear drives




14.4 Parameterization14.4.1 General

IndraWorks allows entering or editing certain parameters and executing com‐mands during commissioning by means of menu-driven dialogs and list rep‐resentations or, optionally, via the control terminal.

14.4.2 Entering motor parameters

Motor parameters are specified by Rexroth and cannot bechanged by the user. If these parameters are not available, com‐missioning is not possible! In this case, please contact yourRexroth Sales and Service Facility.

Activation of the motor immediately after mo‐tor parameter input may result in injury andmechanical damage! The motor is not yetready for operation simply by entering themotor parameters!

WARNING

⇒ Enter parameters for length measuring system⇒ Check and adjust the measuring system polarity⇒ Configure the commutation settings

The motor parameters can be entered as follows:● Use IndraWorks to load all motor parameters.● Enter the individual parameters manually via the controller● Load a complete parameter set at serial machines via the controller or

IndraWorks

14.4.3 Motor parameter at parallal arrangementAre two linear motors operated in a control device, the following parametershave to be adjusted when commissioning:

Parameter Designation Adjustment factor

P-0-4016 Direct-axis inductance of motor x 0.5

P-0-4017 Quadrature-axis inductance of motor x 0.5

P-0-4048 Motor winding resistance x 0.5

S-0-0106 Current loop proportional gain 1 x 0.5

S-0-0109 Motor peak current x 2

S-0-0111 Motor current at standstill x 2

Tab. 14-1: Parameter adjustment at parallel arrangement

A smaller controller can be used, if the maximum possible contin‐uous nominal force or the maximum possible peak force of themotor is not required. In this case, re-adjust the configured cur‐rents to the selected controller. Therefor, use Rexroth IndraSize(see Chapter 4.2 ).

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14.4.4 Entering length measuring system parameterEncoder type The type of the length measuring system has to be defined. By means of pa‐

rameter P-0-0074, Encoder type 1.

Encoder type P-0-0074

Incremental measuring system 2

Absolut encoder with ENDAT interface 8

Incremental encoder with Hall sensor14 or 15

(depending from Hardware configuration)

Tab. 14-2: Defining the encoder type

Detailed descriptions can be found in the firmware or parameterdescription of the drive controller used.● Rexroth IndraDrive MPx-xx Parameter Description,

MNR R911328651● Rexroth IndraDrive MPx-xx Parameter description,

MNR R911328651● Rexroth IndraDrive Firmware MPx-xx Functional Description,

MNR R911328670● Rexroth IndraDrive MPx-xx Application Manual,

MNR R911326767

Signal period Linear scale for linear motors generate and interpret sinusoid signals. Thesine signal period has to be entered in parameter S-0-0116, Resolution offeedback 1.Please also observe the information provided by the measuring system man‐ufacturer for resolution of encoder signals.




14.4.5 Entering drive limitations and application-related parametersDrive limitations The drive limitations that can be set, include:

● Current limitation● Force limitation● Velocity limitations● Travel range limitations

Application-related parameters Application-related drive parameters include, for example, parameterizationof the drive fault reaction.

Detailed descriptions can be found in the firmware or parameterdescription of the drive controller used. See also chapter 14.4.4 "Entering length measuring system parameter" on page 171.

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14.5 Determining the polarity of the linear scaleIn order to avoid direct feedback in the velocity control loop, the effective di‐rection of the motor force and the count direction of the length measuringsystem must be identical.

Different effective directions of motor forceand count direction of the encoder systemcause uncontrolled movements of the motorupon switch-on!

WARNING

⇒ Secure against uncontrolled movement⇒Setting of the effective direction of the motor force identically to the countingdirection of the length measuring system

Effective direction of motor force The following applies for setting of the correct encoder polarity:The effective direction of the motor force is always positive in the direction ofthe cable connection of the primary part.

① Force directionFig. 14-2: Effective direction of motor force

Effective direction of the motorforce = Counting direction of the

length measuring system

In case of motion of the primary part in the direction of the cable connection,the counting direction of the length measuring system must also be positive:

① Force direction② Counting direction③ Length measuring systemFig. 14-3: Effective direction of the motor force = Counting direction of the

length measuring system




The encoder polarity is always set in regard to the primary part(cable connection). The installation direction or pole sequence ofthe secondary part does not have any impact on the encoder po‐larity setting.

The encoder polarity is set via parametersS-0-0277, Position encoder type 1 (Bit 3)Position, velocity and force data must not be inverted when the length meas‐uring system count direction is set:S-0-0085, Torque/force polarity parameter: 0000000000000000S-0-0043, Velocity polarity parameter 0000000000000000S-0-0055, Position polarity 0000000000000000

14.6 Commutation adjustment14.6.1 General

The force of the synchronous linear motor can only develop to a maximumand constant degree, if the commutation angle is set correctly.

Commutation adjustment always has to be performed in the fol‐lowing cases:⇒ Initial commissioning⇒ Modification of the mechanical attachment of the linear scale⇒ Length measuring system replacement⇒ Modification of the mechanical attachment of the primary and/orsecondary part

This procedure ensures that the angle between the current vector of the pri‐mary part and the flux vector of the secondary part is always 90°. The motorsupplies the maximum force in this state.

Adjustment procedure Different commutation adjustment procedures have been implemented in thefirmware. The following figure shows the connection between the lengthmeasuring system used and the procedure to be applied.

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Fig. 14-4: Procedure for commutation adjustment for ironless synchronous line‐ar motors

Observe the following requirements for commutation adjustment:⇒ Effective direction of the motor force = Counting direction of thelength measuring system⇒ Correct motor and encoder parameterization⇒ Complying with the described setting procedures⇒ Appropriate parameterization of current and velocity controlloops⇒ Correct connection of motor power cable⇒ Protection against uncontrolled movements

Errors in commutation adjustment can resultin malfunctions and/or uncontrolled move‐ments of the motor!

DANGER

Take care when carrying out the commutation adjustment. For commutation,observe the detailed information in the documentation under chapter 14.4.4 "Entering length measuring system parameter" on page 171.




Motor connection The individual phases of the motor power connection have to be assignedcorrectly.

Parameter checking To ensure proper commutation adjustment, the following parameters shouldbe checked again:

Ident number Description Designation/function

S-0-0085 Torque/force polarity pa‐rameter

Refer to Parameter De‐scription● Rexroth IndraDrive

MPx-xx,MNR R911328651

● Rexroth IndraDriveMPx-xx,MNR R911297317

S-0-0043 Velocity polarity parameter

S-0-0055 Position polarity

P-0-4014 Type of motor

P-0-0018 Number of pole pairs/polepair distance

S-0-0116 S-0-0116, Encoder 1 reso‐lution

P-0-0522 Commutation adjustmentcontrol word

P-0-0074 Encoder type 1 (motor en‐coder)

Tab. 14-3: Parameters to be checked before commutation adjustment

14.6.2 Sinusoidal procedureYou will find limitations and detailed notes about the sinusoidal procedure in● Rexroth IndraDrive Firmware MPx-xx Functional Description,

MNR R911328670● Rexroth IndraDrive MPx-xx Application Manual, MNR R911326767

14.6.3 Hall sensor procedureThe Hall sensor procedure is applied if an incremental measuring system isused in combination with a Hall unit in the primary part. Also observe the in‐formation on the Hall unit in chapter 7.1 "Hall unit" on page 77.

Commutation by means of analogHall unit

For operation on Rexroth IndraDrive Cs, the following sercos parametersmust be edited before commissioning.

Ident number Description Value

P-0-0508(for MCP020)

Commutation offset1) 590

P-0-0508(for MCP030 ... 070)

Commutation offset1) 922

P-0-0074 Encoder type 1 (motor encoder) 15

1) The parameter is used to enter the motor depending constants.It is not the actually commutation offset. This is displayed with‐in parameter P-0-0521 “Effective commutation offset” after au‐tomatic calculation.

Tab. 14-4: Parameters to be checked before commutation adjustment

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With the above-specified settings, the effective commutation offset(P-0-0521) is automatically calculated on switching to operating mode. Thedrive is ready for power activation.

The procedure “Reference point optimum commutation offset”cannot be used in the case of analog Hall units, as the necessaryparameter P-0-0508 already uses the procedure “Commutationvia analog Hall units”.

Commutation by means of digitalHall unit

For operation on Rexroth IndraDrive Cs, the following sercos parametersmust be edited before commissioning:

Ident number Description Value

P-0-0509(for MCP020)

Rough commutation offset1) 946

P-0-0509(for MCP030 ... 070)

Rough commutation offset1) 62

P-0-0074 Encoder type 1 (motor encoder) 23

1) The parameter is used to enter the motor depending constants.It is not the actually commutation offset. This is displayed with‐in parameter P-0-0521 “Effective commutation offset” after au‐tomatic calculation.

Tab. 14-5: Parameters to be checked before commutation adjustmentWith the above-specified settings, the effective commutation offset(P-0-0521) is automatically calculated on switching to operating mode. Com‐mutation by means of digital Hall unit only enables reaching of an electricalaccuracy of +/- 30°. In this respect, a maximum power loss of 14 % is to beexpected.Hence the maximum motor force is available, a “Reference point optimumcommutation offset” must be stored on the reference point.Procedure at IndraDrive Cs:1. Activate initial commissioning mode (P-0-0522, bit 15)2. Carry out commutation adjustment using the sinusoidal procedure.3. Switch axis to "AF".4. Start fine commutation.5. Initiate reference point run.

If the reference point is reached, the "reference point of optimum com‐mutation offset" (P-0-0508) is placed there.

6. Deactivate initial commissioning mode.On each restart of the machine, the rough commutation offset (+/- 30°) is de‐termined by switching to operating mode. The drive may now run to the refer‐ence point with reduced force. If the reference point is reached or passed, theoptimum reference point for the commutation offset is applied by the driveand the maximum force is available to the axis.

14.6.4 Measuring procedure: Measuring of the relation between primary andsecondary part

For commutation setting, this procedure requires determination of the relativeposition of the primary part in relation to the secondary part. This procedurehas the advantage that commutation adjustment does not require any power




switching and axis motion. Commutation adjustment only needs to be carriedout on initial commissioning.

This procedure requires an absolute length measuring system.

Measuring of the relative positionof the primary to the secondary

part

Depending on the accessibility of the primary and secondary part in the ma‐chine or system, the relative position of the primary to the secondary partmay be calculated in different ways:

a Relative position reference point ①b Relative position reference point ②lp Primary part lengthFig. 14-5: Measuring of the relative position of the primary to the secondary

part

The position of the primary part must not be changed before theprocedure for commutation adjustment is completed!

Calculation of P-0-0523, Commu‐tation adjustment measured value

The input value for P-0-0523 that is required for calculating the commutationoffset, is determined from the measured relative position of the primary partwith respect to the secondary part (Fig. 14-5, distance a or b, depending onaccessibility), and a motor-related constant kmx (Fig. 14-6 and Fig. 14-6).

P-0-0523 Commutation adjustment measured value in mma Relative position reference point ① in mm (Fig. 14-5)b Relative position reference point ② in mm (Fig. 14-5)kmx Motor constant for commutation adjustment in mmlp Primary part length in mmFig. 14-6: Calculation of P-0-0523, Commutation adjustment measured value

Ensure that the sign is correct when you determine P-0-0523,Commutation adjustment measured value. If P-0-0523 is deter‐mined with a negative sign, this must also be entered in the be‐ginning of the setting procedure.

Motor constant kmx for commuta‐tion adjustment

Primary part kmx in mm

MCP020 24.1

MCP030 / 040 / 070 49.6

Tab. 14-6: Motor constant kmx for commutation adjustment

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Example at MCP040C for reference point ➀a = 100 mm , kmx = 49.6 mmP-0-0523 = a - kmx = 100 mm - 49.6 mm = 50.4 mm Example at MCP040C for reference point ②b = 20 mm, kmx = 49.6 mm, lp = 187 mmP-0-0523 = -b - lp -kmx = -20 mm - 187 mm - 49.6 mm = - 256.6 mm

Activation of commutation adjust‐ment command

Prerequisites:1. The drive must be in status A0-13 during the following adjustment pro‐

cedure (= ready for power switching).2. The position of the primary part or the slide must not have changed after

measuring of the relative position of the primary to the secondary part.After the determined value P-0-0523 (Commutation adjustment measuredvalue) is entered, command P-0-0524 (D300 Commutation adjustment com‐mand) has to be started. In this process, the commutation offset is calculated.

If the drive is in command start "AB" (drive ready for operation),the commutation offset with the selected procedure (saturation orsinusoidal procedure) is determined for automatic commutation.

Afterwards, the command is to be cleared.

14.7 Setting and optimizing the control loop14.7.1 General procedure

The control loop settings in a digital drive controller have an essential impor‐tance for the properties of the servo axis. The control loop structure consistsof a cascaded position, velocity and current controller. Which controller is ac‐tive is defined by the operation mode.

Defining the control loop settings requires the corresponding ex‐pertise.

The procedure for control loop optimization (current, velocity and positioncontroller) at linear direct drives corresponds to the procedure for rotary servodrives. Only the setting limits of linear drives are higher.




Fig. 14-7: Setting and optimizing the control loop of synchronous linear motors

For additional and detailed information, refer to● Rexroth IndraDrive Firmware MPx-xx Functional Description,

MNR R911328670● Rexroth IndraDrive MPx-xx Application Manual,

MNR R911326767

Automatic control loop setting Rexroth drive controllers enable automatic control loop setting.Filtering mechanical resonance vi‐

brationsDigital drives from Rexroth are able to provide a narrow-band suppression ofvibrations that are produced due to the power train between motor and me‐chanical axis system. This results in increased drive dynamics with good sta‐bility.The mechanical system of the slide that is moved by the linear drive is stimu‐lated to vibrate mechanically due to the position and/or velocity return withinthe closed control loop. This behavior, known as "Two-mass vibrational sys‐tem", is mainly in the frequency range from 400 to 800 Hz. It depends on therigidity of the mechanical system and the spatial expansion of the system.

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In most cases, this "Two-mass vibrational system” has a clear resonant fre‐quency that can be selectively suppressed by a rejection filter installed in thedrive.When the mechanical resonant frequency is suppressed, the dynamic prop‐erties of the velocity control loop and of the position control loop may, undercertain circumstances, be improved as compared with closed-loop operationwithout rejection filter.This leads to an increased profile accuracy and shorter cycle times for posi‐tioning processes at a sufficient distance to the stability limit.Rejection frequency and bandwidth of the filter can be selected. The rejectionfrequency is the frequency with the highest attenuation. The bandwidth de‐fines the frequency range in which the attenuation is less than –3 dB. A high‐er bandwidth leads to less attenuation of the rejection frequency!

Fig. 14-8: Amplitude response of the rejection filter in relation to the bandwidth,qualitative




14.7.2 Parameter value assignments and optimization of Gantry axesGeneral

Prerequisites:● Parametrization or axes is realized identically● Parallelism of guides of Gantry axes● Parallelism of length measuring systems● The axes are registered as individual axes in the control unit

For compensation of alignment errors between two length meas‐uring systems or the mechanical system, drive-internal axis errorcorrection procedures can be applied. Please refer to the corre‐sponding description of functions of the drive controller for a de‐scription of the operational principle and the parameter settings.

Fig. 14-9: Possible alignment errors at length measuring systems of Gantry ax‐es

ParametrizationFor operation of Gantry axes, identical parameterization of the following pa‐rameters must be ensured:● Motor parameter● Polarity parameter for force, velocity and position● Control loop parameterWe have:

kv Position controller kv factor S-0-0104kp Velocity loop proportional gain S-0-0100Fig. 14-10: Proportional gain in position and velocity control loop of both axes

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Velocity loop integral action time(integral part)

For velocity loop integral action time (integral part), the following possibilitiesmust be taken into consideration:

Possibility 1 Possibility 2 Possibility 3 Possibility 4

Alignment of lengthmeasuring systemsand guides

ideal not ideal not ideal not ideal

Integral part in both axes in both axes in one axis only in no axis

Behavior of the axes Tensioning of the me‐chanical system is notrealized as both mo‐tors ideally follow theposition command val‐ue

Both axes workagainst each other un‐til compensation viathe mechanical cou‐pling or until the maxi‐mum current isreached at one or bothdrive controllers andno more control effectcan be achieved

The axis without inte‐gral part allow continu‐ous position offset.The position offset de‐pends on the stiffnessof the mechanical cou‐pling of both axes aswell as the proportionalgains in the positionand velocity controlloop

Both axes allow contin‐uous position offset.The position offset de‐pends on the propor‐tional gains in the posi‐tion and velocity con‐trol loop

Tab. 14-7: Parametrization of the velocity loop integral action time S-0-0101 atGantry axes.

Optimization For optimization of velocity and position control loop, the above-describedprocedure must be observed.

Parameter changes during optimization of Gantry axes must al‐ways be carried out at both axes. If this is not possible, the pa‐rameter changes during optimization should be carried out subse‐quently in small steps at both axes.

14.7.3 Estimating the moved mass using a velocity rampThe moving weight of a machine slide is often not precisely known. This maybe obstructed by subsequently installed attachments, moving components,etc.The procedure described below enables estimation of the moved axis massaccording to recording of a velocity ramp. For example, this enables estima‐tion of the acceleration capacity of the axis.

Preparation Precondition for positioning is oscillographical representation of the followingparameters:● S-0-0040, Velocity actual value● S-0-0080, Torque/force command valueFor this purpose, an oscilloscope or the oscilloscope function of the drive canbe used in combination with IndraWorks or NC.




Fig. 14-11: Oscillogram of velocity and force

m Moved axis mass in kgFN Continuous nominal force of the motor in NFACC Force command value during acceleration in %FDEC Force command value during deceleration in %Δv Velocity change during const. acceleration in m/minΔt Time change during const. Acceleration in sFig. 14-12: Determination of the moved axis mass according to recording of a

velocity rampPrerequisites:1. Correct parameter settings of the rated motor current (basis of representa‐tion S-0-0080)2. Frictional force not directional3. Recording of Δv and Δt at constant acceleration4. Measuring with a motor force between FN and Fmax

The procedure is not suitable or suitable only to a limited extendfor vertical axes due to potential direction-depending forcechanges.

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14.8 Maintenance and checking of motor components14.8.1 General

MCL motor components do not require any maintenance. During operation,however, external influences may cause damage at motor components. With‐in the service intervals of the machine or system, preventive checking of line‐ar motor components should be carried out.

14.8.2 Checking of motor and additional componentsThe following points should be observed and if necessary restored during thepreventive check of motor and auxiliary components:● Noticeable sound during operation● Scratches on primary and secondary part● Dirt (e.g. shavings, dust, grease by guides etc.) within the air gap be‐

tween primary and secondary part● State of power and encoder cables in a drag chain.● State of length measuring system (e.g. contamination)● State of guides (e.g. deterioration of linear guides)

14.8.3 Electrical check of motor componentsElectrical defects at a primary part are can be indicated in advance by meas‐uring the electrical characteristics. The following variables are relevant:● Resistance between motor connecting wires 1-2, 2-3 and 1-3● Inductance between motor connecting wires 1-2, 2-3 and 1-3● Insulation resistance between motor connecting wired and guides

Resistance and inductivity The measured values of resistance and inductance can be compared to thevalues specified in chapter "Technical data". The individual values of resist‐ance and inductance measured between the connections 1-2, 2-3 and 1-3should be identical within a tolerance of ± 5 %. There can be a phase shortcircuit, a fault between windings, or a short circuit to ground if one or morevalues differ significantly. If so, the primary part must be exchanged.

Insulation resistance The insulation resistance measured between the motor connection wires andground should be at least 1 MΩ (MegaOhm). If this value is fallen below, re‐placement of the primary part is recommended.

If necessary, please contact the Bosch Rexroth customer servicefor inspection of the electrical system.




14.9 Operation with third-party controllersRate of rise of voltage The electrical insulation of the motor is subject to a higher dielectric load in

converter mode than when it is operated with a merely sinusoidal source volt‐age. The voltage load of the winding insulation in converter mode is mainlydefined by the following factors:● Crest value of voltage● Rise time of pulses at the motor terminals● Switching frequency of final converter stage● Length of power cable to the motorMain components are the switching times of the final converter stage and thelength of the power cable to the motor. The rates of rise of the voltage occur‐ring at the motor may not exceed the pulse voltage limits specified inDIN VDE 0530-25 (VDE 0530-25):2009-08 (picture 14, limit curve A), meas‐ured at the motor terminals of two strands in relation to the rise time.

These limits are complied with by the final stages of IndraDriveconverters.

14.10 Environmental protection and disposal14.10.1 Environmental protection

Production processes The products are manufactured in energy- and resource-optimized produc‐tion processes which allow re-using and recycling the resulting waste. Weregularly try to replace pollutant-loaded raw materials and supplies by moreenvironment-friendly alternatives.

No release of hazardous substan‐ces

Our products do not contain any hazardous substances which may be re‐leased in case of appropriate use. Normally, our products will not have anynegative influences on the environment.

Significant components Significant components of our products are:Electronic devices Motors∙ Steel ∙ Steel / Stainless steel∙ Aluminum ∙ Aluminum∙ Copper ∙ Copper∙ Plastics ∙ Brass∙ Electronic components ∙ Magnetic materials ∙ Elektronic components

14.10.2 DisposalReturn of products Our products can be returned to us for disposal free of charge. However, this

requires that the products be free from oil, grease or other dirt.Furthermore, the products returned for disposal may not contain any undueforeign material or foreign components.Deliver the products "free domicile" to the following address: Bosch Rexroth AG Electric Drives and Controls Buergermeister-Dr.-Nebel-Straße 2 97816 Lohr am Main, Germany

Packaging Packaging materials consist of cardboard, wood and polystyrene They canbe recycled anywhere without any problem.

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For ecological reasons, please refrain from returning the empty packages tous.

Batteries and accumulators Batteries and accumulators can be labeled with this symbol.

The symbol indicating "separate collection" for all batteries and accu‐mulators is the crossed-out wheeled bin.End users in the EU are legally bound to return used batteries and accumula‐tors. Outside the validity of the EU Directive 2006/66/EC, the particularly ap‐plicable regulations must be followed.Batteries and accumulators can contain hazardous substances which canharm the environment or people's health when improperly stored or disposedof.After use, the batteries or accumulators contained in Rexroth products mustbe properly disposed of according to the country-specific collection systems.

Recycling Most of the products can be recycled due to their high content of metal. Inorder to recycle the metal in the best possible way, the products must be dis‐assembled into individual assemblies.Metals contained in electric and electronic assemblies can also be recycledby means of special separation processes.Plastic parts of the products may contain flame retardants. These plasticparts are labeled according to EN ISO 1043. They have to be recycled sepa‐rately or disposed of according to the applicable legal provisions.




15 Service and supportOur worldwide service network provides an optimized and efficient support.Our experts offer you advice and assistance should you have any queries.You can contact us 24/7.

Service Germany Our technology-oriented Competence Center in Lohr, Germany, is responsi‐ble for all your service-related queries for electric drive and controls.Contact the Service Hotline and Service Helpdesk under:

Phone: +49 9352 40 5060Fax: +49 9352 18 4941E-mail: [email protected]: http://www.boschrexroth.com

Additional information on service, repair (e.g. delivery addresses) and trainingcan be found on our internet sites.

Service worldwide Outside Germany, please contact your local service office first. For hotlinenumbers, refer to the sales office addresses on the internet.

Preparing information To be able to help you more quickly and efficiently, please have the followinginformation ready:● Detailed description of malfunction and circumstances● Type plate specifications of the affected products, in particular type co‐

des and serial numbers● Your contact data (phone and fax number as well as your e-mail ad‐

dress)


Service and support


mailto:[email protected]

http://www.boschrexroth.com

IndexAAcceleration.......................................................... 4Acceleration capability...................................... 110Acceleration force............................................. 110Accessories......................................................... 77Accumulators.................................................... 187Active height....................................................... 99Additional components.......................................... 7Air gap................................................. 45, 112, 161Air humidity....................................................... 101Air temperature................................................. 101Alignment............................................................ 48Ambient temperature.................................. 27, 100Ambient temperatures......................................... 21Arranged motor components

Parallel connection....................................... 114Arrangement motor components

Primary parts in a row.................................. 119Secondary parts........................................... 119Several motors per axis............................... 113

Arrangement of motor components.................. 159Double comb arrangement.......................... 118Gantry arrangement..................................... 118Single arrangement...................................... 112

AssemblyConnection cable power................................ 85Hall unit connection cable.............................. 92

Attractive forces.................................................... 3Auxilliary device.................................................. 80Axis construction................................................. 97Axis cover systems........................................... 123Axis covering systems

Bellow covers............................................... 123Roller covers................................................ 123Telescopic covers........................................ 123

BBatteries............................................................ 187Braking devices................................................. 122

CCable selection................................................... 86Certificates

CE................................................................ 102Certifications..................................................... 102

China RoHS 2.............................................. 103EAC.............................................................. 102RoHS........................................................... 103

Checking of motor componentsby customer................................................. 185

Checking the motor componentsFactory-checked.......................................... 155

Cinematic chains............................................... 110Coil body............................................................. 97Commissioning

Drive limitations............................................ 172Length measuring system parameter.......... 171Motor parameters......................................... 170Procedure.................................................... 168Requirements............................................... 167Tools............................................................ 168

Commutation....................................................... 77Commutation adjustment.......................... 167, 174

Hall sensor procedure.................................. 176Measuring procedure................................... 177Sinusoidal procedure................................... 176

Commutation offset angle................................... 77Connect

Length measuring system.............................. 94Connection........................................................ 165

Analog Hall unit.............................................. 94Digital Hall unit............................................... 93Hall unit.......................................................... 90Power............................................................. 86Power connection.......................................... 83Temperature sensor....................................... 90

Connection assignmentConnection cable Hall unit............................. 92Connectrion cable length measuring sys‐tem................................................................. 95

Connection cable................................................ 84Allowed bending radius.................................. 84Cable break.............................................. 85, 91Cross section control wires............................ 84Cross section power wires............................. 84Diameter........................................................ 84Fixed installation...................................... 85, 91

Connection cable Hall unit.................................. 90Allowed bending radius.................................. 91Cross section control wires............................ 91Diameter........................................................ 91fix installation................................................. 91flexible installation.......................................... 91

Contained substancessee "Significant components"...................... 186

Continuous nominal force..................... 22, 25, 149Control quality................................................... 110Control systems................................................ 124Controller............................................................ 77Controller optimization...................................... 167Cooling.......................................................... 62, 97

Power loss................................................... 105Cooling down.................................................... 107Corrosion protection............................................ 98Cross-table........................................................ 110

DDC bus capacity................................................ 127DC bus short-circuit.......................................... 128DC bus voltage............................................. 21, 22


Index

Deactivation...................................................... 125Deceleration force............................................. 110Degree of protection........................................... 27Delivery status.................................................. 155Detent force.......................................................... 3Dimension sheets............................................... 45Dimensional sheets

MCP015......................................................... 50MCP020......................................................... 52MCP030......................................................... 54MCP040......................................................... 56MCP070......................................................... 58MCS015......................................................... 51MCS020......................................................... 53MCS030......................................................... 55MCS040......................................................... 57MCS070......................................................... 59

Dimensions......................................................... 48Disposal............................................................ 186Drive controller............................................ 22, 124Drive power....................................................... 150Drive system....................................................... 11Duty cycle......................................................... 149Dynamic................................................................ 3

EEffective values................................................... 21Efficiency........................................................... 153Electric drive system........................................... 11Electrical connection........................................... 62EMERGENCY STOP........................................ 125Encoder polarity................................................ 167End position shock absorber............................. 123Environmental conditions.......................... 101, 112Environmental protection.................................. 186ESD..................................................................... 90ESD protection............................................ 91, 108

Protective foil................................................. 90Excitation of vibrations...................................... 110

FFastening holes................................................... 48Fastening rail...................................................... 98Fastening screws................................................ 80Fastening type primary part.............................. 163Fastening types secondary part ....................... 161Feed force........................................... 99, 135, 149

Inserted force reduction............................... 108Reduced covering........................................ 108

Feed forces................................................... 4, 113Fields of application.............................................. 1Final over temperature...................................... 106Flange socket power........................................... 85Force constant.............................................. 21, 25Force density........................................................ 3Force generation................................................. 97Force reduction................................................. 109

ForcesReactive forces............................................ 110

Foreign bodies.................................................... 97Frame length....................................................... 99Frame lengths..................................................... 62Frame shape....................................................... 62Frame size.............................................. 62, 63, 99Frame sizes........................................................ 99Friction.............................................................. 112

GGantry arrangement............................ 77, 113, 133Gantry axes

Parameter value assignments and opti‐mization........................................................ 182

Gantry structure................................................ 110Grinding traces.................................................. 112Grounding........................................................... 85

HHalf-timbered construction................................ 110Hall unit............................................... 2, 62, 77, 90

Assembly....................................................... 80Disassembly................................................... 80ESD protection............................................... 80Installation space........................................... 80

Hall unit - adapter box......................................... 81Hall unit analog................................................... 62Hall unit digital..................................................... 62Hall unit mode of functioning............................... 77Hall unit ordering code ....................................... 81Handling............................................................ 155Hazardous substances..................................... 186Heat loss

Heat loss dissipation.................................... 129Utilization rate.............................................. 129

Heating up......................................................... 106Helpdesk........................................................... 189High rigidity....................................................... 110Holding devices................................................. 122Hotline............................................................... 189Humidity.............................................................. 97

II-form................................................................... 98IATA 953........................................................... 157Identification........................................................ 74IndraDrive Cs.................................................... 134IndraSize............................................................. 26IndraWorks........................................................ 168Induced motor voltage........................................ 25Inductivity............................................................ 21Initial commissioning........................................... 77Installation

Electrical connection.................................... 165Installation altitude............................................ 100Installation dimensions.................................. 45, 48

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Index


Frame size MCL015....................................... 46Frame size MCL020 ... 070............................ 47

Installation modes..................................... 129, 131Installation mode A...................................... 131Installation mode B...................................... 131Installation mode C...................................... 131Installation mode D...................................... 131

Installation sizes................................................ 159Installation tolerances......................................... 21Instructions on use................................................ 9

Appropriate use................................................ 9Inappropriate use........................................... 10

Insulation resistance......................................... 185Insulation system.............................................. 186Iron yoke............................................................... 2

KKTY84-130; see also temperature sensor.......... 90

LLength measuring system............. 94, 97, 111, 120

Measuring system cables............................ 121Length measuring systems

Selection criteria.......................................... 120Linear guide........................................................ 97Linear guiding................................................... 121Loop bandwidth................................................. 110

MMachine base body deformation....................... 111Machine construction

Integrating linear scale................................. 111Mass reduction............................................. 110Mechanically coupled axes.......................... 110Requirements............................................... 110Rigidity......................................................... 110

Magnetic field...................................................... 77Malfunction........................................................ 125Mass primary part............................................... 25Mass secondary part........................................... 26Maximum current................................................ 25Maximum DC bus voltage MCP015.................... 27Maximum DC bus voltage MCP020 ... 070......... 27Maximum force............................................. 22, 25Maximum velocity............................................... 25MCL - Motor Coreless Linear................................ 2MCS - Motor Coreless Secondary part................. 2Mechanical braking devices.............................. 126Mechanical design.............................................. 63Mechanical force effect..................................... 112Mechanical protection......................................... 63Mode of functioning............................................. 97Modular system................................................... 99Mold.................................................................... 97Motor breakdown.............................................. 112Motor characteristic curve................................... 22

Characteristic curve....................................... 21

Motor coupling.................................................. 110Motor damage................................................... 112Motor design

Primary part................................................... 97Secondary part............................................... 98

Motor dimensionTrapezoidal velocity profile.......................... 145

Motor dimensioning........................................... 135Average velocity........................................... 140Feed forces.................................................. 137Movement equations.................................... 136Sinusoidal velocity profile............................. 146Trapezoidal velocity profile.......................... 141

Motor installation space.................................... 112Motor parameters.............................................. 170Motor temperature monitoring........................... 107Motor variants..................................................... 61Motor winding temperature................................. 21Motor-control combinations............................... 133Moving masses......................................... 110, 167

NNatural convection...................................... 97, 129Natural frequencies........................................... 110Natural frequency.............................................. 110Noise emission.................................................. 104Nominal velocity............................................ 22, 25NYCe 4000....................................................... 133

OOperating behavior............................................. 21Operation with third-party controllers................ 186Options................................................................ 77Ordering code

Hall unit.......................................................... 81Ordering designations......................................... 61Other designs................................................ 62, 63Output

Energy regeneration.................................... 152Overheating of the motor.................................. 132

PPackaging................................................. 155, 186Parallel arrangement................................... 87, 170Parallel connection............................................ 113Parallel connection, collective power cable........ 89Parallel connection, separate power cables....... 89Parallelism............................................ 45, 48, 160Parameters....................................................... 167Parasitic effects..................................................... 3PELV................................................................... 15Performance spectrum.......................................... 4Permanent magnets........................................ 2, 98Phase position.................................................... 77Polarity of the linear scale................................. 173Pole pair width.............................................. 25, 77Position accuracy...................................... 128, 129


Index

Position information............................................ 77Position resolution..................................... 128, 129Power

Continuous power........................................ 150Maximum output.......................................... 151Power loss................................................... 152

Power cable........................................................ 85Collective power cable................................... 88Installation...................................................... 88Separate power cable.................................... 88

Power connector................................................. 85Power loss................................................ 105, 132power outage.................................................... 126Power supply modules...................................... 124Precision............................................................... 3Primary part........................................................... 2Primary part carrier............................................. 97Process forces.................................................. 110Product identification........................................... 74Product ordering................................................. 61Product selection................................................ 61Production processes....................................... 186Projections........................................................ 110Protection mode........................................ 102, 112Protection of motor installation space............... 112Protective conductor........................................... 85Protective extra-low voltage................................ 15Protective foil.................................................... 108PWM-Frequency................................................. 25

RRated current...................................................... 25

Limitation...................................................... 132Rated feed force............................................... 105Rated power loss................................................ 25Recycling.......................................................... 187Repairs................................................................ 61Resonant frequency.................................. 110, 181Return of products............................................ 186

SSafety instructions for electric drives andcontrols............................................................... 11Saturation effect.............................................. 3, 25Scope of delivery................................................ 97Scratch-formation.............................................. 112Screw-in depth.......................................... 162, 163Secondary part...................................................... 2Segment lengths................................................. 63Serial number MCP............................................. 74Serial number MCS............................................. 75Service hotline.................................................. 189Setting and optimizing the control loop............. 179SHL03.1.............................................................. 93SHL03.1 adapter box.......................................... 93Shock absorber................................................. 123Short-circuit loss............................................... 105

Shutdown temperature........................................ 27Significant components..................................... 186Skilled personnel............................................... 159Spare parts......................................................... 61Specifications...................................................... 45Speed.................................................................. 22Standards.............................................................. 7Standstill operation........................................... 132Start-up

Parameterization.......................................... 170Start-Up

Mass definition............................................. 183Storage............................................................. 157Storage temperature........................................... 27Storage time...................................................... 158Strain relief.......................................................... 85Support............................................................. 189Symmetry.............................................. 45, 48, 160

TT-form.................................................................. 98Technical data

Frame size 015.............................................. 28Frame size 020.............................................. 30Frame size 030.............................................. 33Frame size 040.............................................. 36Frame size 070.............................................. 40

Temperature model............................................. 90Temperature monitoring

Pre-warning temperature............................. 107Shut-off temperature.................................... 107Temperature sensor KTY84-130................. 107

Temperature sensor............................................ 90Polarity........................................................... 90

Thermal class...................................................... 27Thermal connection.................................. 129, 135Thermal coupling.......................................... 22, 97Thermal time constant........................ 25, 105, 132Tightening torque...................................... 162, 163Tightening torque Hall unit.................................. 80Tolerances.................................................... 25, 48Total duty cycle time......................................... 149Touch of electrically active parts......................... 97Transport........................................................... 156Transport temperature........................................ 27Travel length....................................................... 45Travel velocity..................................................... 25Traverse path length........................................... 97Type codes......................................................... 61Type designation MCP........................................ 74Type designation MCS........................................ 75Type plates................................................... 74, 75

VVelocity......................................................... 4, 135Velocity resolution..................................... 128, 129Vertical axes....................................................... 77

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Index


Vertical axis....................................................... 119Vibrations.......................................................... 110Voltage constant................................................. 25

WWarning notes................................................... 155Warning temperature.......................................... 27Weight compensation....................................... 119Winding............................................................... 62Winding inductivity.............................................. 25Winding protection.............................................. 90Winding resistance.............................................. 25Winding temperature................................. 105, 107Wire designation................................................. 84Wire end ferrules................................................. 84


Index

Notes


Bosch Rexroth AGP.O. Box 13 5797803 Lohr a.Main, GermanyBgm.-Dr.-Nebel-Str. 297816 Lohr a.Main, GermanyPhone +49 9352 18 0Fax +49 9352 18 8400www.boschrexroth.com/electrics

*R911330592*R911330592

DOK-MOTOR*-MCL********-PR06-EN-P

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